Polini Evolution Build

[Crazy Scooter]

Started a new project about a month ago.... my Polini Evo 70 Aerox. Hope to order the Evo 2 bore kit tomorrow and start porting the cases asap. Bought an Evo exhaust yesterday off ebay but i'm trying to find out whether its the Evo 2 or the Evo 1 system? The header has a 30mm Round opening. Heres a few pics, Would like to know which one it is as its bugging me :confused: Thanks :)

[rydah]

thats a evo 2 pipe. the evo 1 has a lot smaller header pipe.

[Crazy Scooter]

thats a evo 2 pipe. the evo 1 has a lot smaller header pipe.

Thanks Rydah..... You've just made my day ,,,... . More to come later :)

[rydah]

how much did you get that pipe for. also what are your plans for it.

[Crazy Scooter]

how much did you get that pipe for. also what are your plans for it.

The pipe cost me £140 GBP which is £65 less than RRP at SIP.

Plans at the moment are to go 100% polini evo 2 on most things so.... Evo2 Bore 70cc (ordered yesterday), Evo2 Crank.... way expensive but hopefully worth it???, Evo 9 roler vario and rear pulley, evo2 bell, malossi delta clutch 107, polini gears (not sure of the ratio's but the ones recommended in the Evo book), mvt premium ignition if i can ever get one or something similar.

I was going to go MHR all the way but when i found the exhaust i changed my mind :)

The bike is an Aerox, bought a brand new frame and it should look similar to the Aerox 100 i build last year but without the koso rs dyno guage as that was a huge waste of money.

Thats all i can think of at the moment and breakfast is ready :) Cya

It is an LC setup btw

[rydah]

that evo crank cost way too much, you could have saved money and got another race crank, but anyways good luck with your build. oh yeah i bought a evo2 pipe from my friend almost a year ago and i paid $100 for it.

[Crazy Scooter]

that evo crank cost way too much, you could have saved money and got another race crank, but anyways good luck with your build. oh yeah i bought a evo2 pipe from my friend almost a year ago and i paid $100 for it.

Well the cylinder i have bought but the crank i haven't ordered yet, the cheapest evo2 crank i can find is 275 euro. Which crank would you suggest getting? Good deal on your exhaust... i was lucky but not that lucky ;) How does it compare to something like a c21?

[rydah]

i havent compared this pipe to a c21, but on my friends 100% polini evo bike he got over 85mph with that pipe so it does work pretty good. you can go with pretty much any of the race cranks, bgm, hebo, metra kit, malossi, polini. you can find something for less then 200 bucks that will work really good and use the rest of the money for extra parts. if you set up everything right this build should smoke your 125 build.

[mikal]

If you're going full evo, why not go with the evo ignition?

I gotta vouch for the BGM pro evo crank. Its held up well with my A/C MHR kit thats
revving in at 13.8K.

[Crazy Scooter]

If you're going full evo, why not go with the evo ignition?

I gotta vouch for the BGM pro evo crank. Its held up well with my A/C MHR kit thats
revving in at 13.8K.

Thanks Mikal, i'm still considering my crank options at the moment, i would really prefer to get the genuine evo crank but will have to see how the cash goes. Also quality kinda bothers me.... where is the BGM one made? Also i know about the polini inner rotor but i haven't seen an Evo one yet, i'm also looking at the MVT one as it plugs straight into the aerox loom and everything is supposed to work like stock but no one has any of them that i have found :(

[Crazy Scooter]

if you set up everything right this build should smoke your 125 build. I'm counting on it :race:

[mikal]

The polini "inner" rotor is EVO. Thats it. Well, at least the box says polini evolution.

I'm pretty sure that the BGM is a Taiwan special. I got it because it was recommended from my "scooter tuner mentors".

Here is a list of parts you may find intresting......maybe not.
http://www.scooterinvasion.net/forum/viewtopic.php?t=253

[rydah]

its your money brah, you can spend more if you want, but the results are going to be the same. go to some euro forums and ask around what is a good crank for your set up. the thing is to try and save as much money as possible when building these race set ups. also that polini rotor kit is not a inner, the older evo rotor kit was a inner, its just like the malossi one, the new one is the one with lighting so you can ride at night legal. thats the one you want. i have the malossi one, but i will be selling that soon so i can get the polini rotor with lighting because i use my scooters on the streets.

[Crazy Scooter]

Here is an update on the project; In the end i decided to get the EVO 1 Crank as i felt the newer version was not worth paying nearly double and when it arrived i was happy to find it looks identical to the evo 2 crank but without the newer silver colored conrod.

Anyway i have ported the cases to what i think is going to work, did some flow work and reshaped the carters with epoxy stick first, then ground it to shape and then coated it with West System epoxy and sanded it smooth. I'm hoping it will stay cool so the epoxy doesn't come away but time will tell on that one.... didn't seem to be affected by heating the cases for assembly so i think it should be fine.

Tonight i installed the new crank with SKF C4 bearings and all new seals, turns really smoothly :) I must say i am really impressed with the crank quality, it is really awesome :)

I have the cylinder now... the Evo2 70cc but i am waiting for new cylinder studs etc from yamaha so the project takes a tempory break whilst the parts arrive. The exhaust is oval... from what i have read this is good to reduce turbulence, is that correct? Also would it hurt to match it to the exhaust header? Any suggestions on porting for the bore or should i just leave it as standard?

Still can't get hold of the MVT ignition i wanted so the Polini External rotor system will be ordered shortly along with the evo speed drive and rear pulley.

Any suggestions on which carb to get? I am planning on rear mounting it as i still have a new mhr viton manifold leftover from the last aerox so it needs to be able to function at quite an angle. Polini recommend a 19mm but it sounds small to me.

I'll try to post some pics later :) Thanks in advance for any advice you can offer.

[rydah]

your set up will work with a 19mm dell, but a 21mm will work better. me and my friends mostly use pwk28mm. i was using a 25mm dell but the 28 pwk seems to work better.

[mikal]

also that polini rotor kit is not a inner, .


Thats why I quoted the "inner" part of the description.


Simon- It's because of the ovaled out exhuast connections that I got the MHR instead of the evo kit. Though, I'm sure it wouldn't take much to brazen(correct term?) some material on the flange, or to just match the exhaust port to the flange.

I suggest going to scooter-shack uk and either posting or PMing MinorConfusion about the aerox.

[Crazy Scooter]

Thanks Mike, I now understand why they it wasn't labeled an evo as it was the inner that was the evo rather than the new outer type i am looking at. Anyway i'm going to go for the new outer polini system as i do need some lights etc, i believe you have the same system..... have you managed to make it charge the battery yet or just power the lights directly?

I read on one of the other forums about brazing the header to match the port but i am a bit reluctant to do that for 2 reasons... 1/ i have no oxy or aceteline gas here. 2/ Why didn't polini do it as it is part of a matched set.... evo bore and exhaust. Seems a little odd to me, anyway i think i am going to just polish the exhaust port and leave it at that for the time being and see how it runs as i'm not sure what i have to gain by matching it up since the exhaust isn't restricting it in anyway.

I will look up scootershack and see what they say.

Heres a few pics of the project and the finished carters.... more later :)

[burnt_toast]

That there is some sexy porting, nice pics

[mikal]

Nice work! Is that matched to the transfer channels on the cylinder, or will you match
the channels to the carters? Also, pay mind to the cylinder skirts that may appear when
looking in the reed cage inlet. I've had some issues with blockage there.

I have the polini ignition still, but its not on. It took me forever to dial in the timing, and
when I finally got it, something happened to the cdi. I have to sent it back to scooter
center. I had to remove the woodruff key(spie) to get the allignment of the flywheel and
stator correct. The battery never held a charge, but it powered my lights consistently.

[Crazy Scooter]

Thanks Guys ! Yes the transfers and boost port on the cylinder are matched to the cases, the case became a little thin on one side and it should have been ground out even more than it was but according to my calcs it would have landed outside of the case had i kept grinding so i put some chem metal for the gasket to rest on and give a better seal.

I know what you're saying about the cylinder skirt blocking it but i am not prepared to grind it away as 1/ its extremely thin 2/ i think it helps direct a certain amount towards the boost port 3/ it needs to be reliable.

Do you think the polini ignition is a worthwhile bet? Sounds like yours failed and i read about someone elses failing a short while ago on provo.

[mikal]

I just made a dumb ass mistake with my kit. They are a great kit if you only need
lights. I have an digital gauge for speed, CHT, fuel, RPM that would go dead more
and more quickly(as the battery became weaker, and held less of a charge). I hated
not knowing those stats.
You could shave the stock flywheel, and get a digitally programmed CDI, then advance
your stator plate 1mm in the counterclock wise position. That setup performs much
better than the stock, and gives full stock ignition system power. When the time comes
that is what I will do, and hopefully get a refund for the polini.

[Crazy Scooter]

I just made a dumb ass mistake with my kit. They are a great kit if you only need
lights. I have an digital gauge for speed, CHT, fuel, RPM that would go dead more
and more quickly(as the battery became weaker, and held less of a charge). I hated
not knowing those stats.
You could shave the stock flywheel, and get a digitally programmed CDI, then advance
your stator plate 1mm in the counterclock wise position. That setup performs much
better than the stock, and gives full stock ignition system power. When the time comes
that is what I will do, and hopefully get a refund for the polini.

I haven't been able to find a manual on the polini system so perhaps you could tell me how you hooked up the power output from the ignition? Also does it output a Regulated AC current of 12v or is it higher?

I hope you get your refund from SC, they have always been quite helpful in the past but when i had a Koso gauge go up in smoke but they did insist on testing it before issuing my refund in the form of a store credit. The testing was done by the distributer and took over 2 weeks :( Just a heads up

[Conor]

Hi Simon. Project looks like it is going good. Still got no luck with the bracket. I'm on Scootershack quite a bit. They have some good tuning advice on there.

[OveRReV]

Crazyscooter,

don't port match the cylinder kit to the exhaust flange of the pipe, do it the other way & braze some metal on the flange & port it to an oval shape like the Evo.

the Evo2 is a good endurance race kit, it doesn't eat rings & pistons as much as the bridged exhaust ports like the Evo1 & MHR Team kits so it'll last a very long time between ring changes, it may not give the highest peak hp but it does give a nice linear powerband which is easy to tune especially with the Evo exhaust, that pipe is a torquer.

for the reedvalves spend the money & get the VForce3 reedcage, best reedcage i ever used, awesome throttle response & great high rpm performance, it should last longer than the Malossi VL14 or Polini reedvalves.

[Crazy Scooter]

Hi Guys,
Many thanks for the input so far, overrev... thanks for the tip on the reeds, will get those underway when some more dough arrives. I think for the time being i'll leave the exhaust as is... no brazing but sometime in the future i'll match it up.

Cheers Connor, if it turns up please let me know.

Here are the latest pics of the project to date, still quite a long way to go as money is the main problem so it should be done in about 2 months hopefully :)

Thanks to Mikal for the last shipment of parts.

More later guys

[Crazy Scooter]

More pics

[Crazy Scooter]

and more pics

[waxhead]

looking good
why did you not port the cases out on the sides to allow the flow to come down past the side of the intake side sleeve

[Crazy Scooter]

looking good
why did you not port the cases out on the sides to allow the flow to come down past the side of the intake side sleeve

Thanks :) Didn't port that area because i felt i had ported it enough and didn't want to grind so much that i'd have to weld it up if it go too thin.