2005 Overrange Help

[Ndog1]

Alright, i just got the new overrange kit (6112811) along with a polini 2G clutch and speedbell. I put it on a 2004 zuma that has a corsa/r kit with reeds and 19mm arreche carb. I am so dissapointed!!! I have 3 zumas and a sr50 so I have had plenty of scooter tuning experience but have
always wanted to dish the big bucks out for an OR. When I heard there was a new one, I sprung. Here is where I need help:

1: I didnt really see anything that was in the belts way, but I ground similar to what jered did anyway.

2. I removed everything from the crank, even the starter gear boss and used the supplied spacer with the kit. Still the front crank nut barely goes on enough for the kick start crown but its not bad. However the 3.3 and 3.8g weights that come with the kit seem way light to pull the tension of that red rear contra spring.

4. Most of all, after putting the torque driver and clutch lineup on the back, I can barely thread my nut halfway on the shaft!! Do I need to grind underneath the pulley on the transmission gear cover or what?

Help me man, I just spent 400 bucks and waited 2 weeks on a setup that sucks right now. More grinding, heavier weights, yellow spring instead of red? The corsa puts out decent power with my shot pipe. I figured it would pull 3.8's.

Thanks guys

Ndog

[str8dum]

yeah you have to keep grinding. The OR is used to allow for lower gearing when using an upgear kit, ie to help return acceleration back to stock-like when you use an up gear. Its design also allows more revs compared to the stock torque driver. You motor isnt a hi-revving one, so the stock driver was prolly just fine in that aspect.

If you dont have an upgear, your top speed will be slower.

Use a lighter torque spring or heavier weights. I'm using 3.5g with a red malossi, and that seems to be pretty standard )some setups use as low as 2g rollers). You are the only person with the 2005 model with the bigger rollers on a Zuma (in this forum), so maybe it doesnt fit at all.... Keep grinding.

[Ndog1]

So is it normal to have the rear clutch bell nut only half threaded with these kits?

Also has anyone had to grind behind the inner pulley on the transmission case?

I know the corsa/r shot combo is not race but it revs higher than most mid street setups. I got plenty of rev when I put the OR on. It just felt like it wasnt putting to the ground , real light feeling. Like Jered said from a stop or under 10mph it does a wheelie but after that its weak. It will keep the rpms up good but doesnt put it down, I feel no torque during full throttle yanks. Do I need like 6 gram weights? Maybe they just decked this one harder for straight 20 + hp 15K rpm race bikes. I guess it is a "racing" transmission. Please someone help me so I can finish the right grinding and try this again.

Ndog

[mikal]

I think you guys are right about the roller weights, go heavier. Got rollers?

[str8dum]

Mine mounted right up, with the same amount of thread showing as the stock pieces. If your does not mount this way, then there is something wrong and I would be very wary about using it.

I only had to grind the cases for the belt. Nothing else.

[Lennox]

The scoot that I got woth the OR already on it was just like you say (clutch nut only half way) It eventually broke the belt, and f'ed up the vari, and the end of tyhe crank. Be carefull...... I am not sure if maybe you and I both got the wrong kit, or if the cases are just not up to spec?

I know that my kit was of the old variaty, but not sure of the model#

Are you going to do the grinding?

[Ndog1]

The kit I have is 6112811. It is the 2005 version of 6111063. These are for the bugeye newer zumas right?

The pulley number is 61 9733.

Maybe someone knows if this is the right stuff.

It is so confusing with bws, euro zuma, jog, horiz, min, short case, long case and malossi site doesnt help much.

thanks guys

[str8dum]

yeah thats the correct model #.

You always buy tranny parts from an Aerox 50

i';d say keep grinding then. Like I said, mine went on like stock

[Crazy Scooter]

yeah thats the correct model #.

You always buy tranny parts from an Aerox 50

i';d say keep grinding then. Like I said, mine went on like stock

I'm not so sure you're correct on the Aerox 50 tranny parts fitting a USA Zuma, If you took the rear wheel of an Aerox 50 and tried it on a Zuma it would not fit. The Aerox 100 wheel would fit tho. Also on http://www.malossi.com/Archivio_Files%5CMONTAGGIO%5C7311061.pdf it states that Part # 6112811 is for Aerox 50 LC, BWS, BWS NG, JOG R, Neo's, Sliders, Why and Zuma. However the correct unit appears to be Part # 6112812 for the Axis, Breeze, Jog, Jog ER, Jog Z, Vino and Zest (ie all the air cooled motors i think). Also the Euro Zuma is not what you're looking for. IMO get the kit swapped for the correct one.

[str8dum]

As I said before, the tranny parts from and aerox 50 are the parts you reference.

The AC jog and US Zuma do NOT have the same transmission. They are short case. The zuma and aerox50 have long case.

Of course the wheel wont fit bc its a disc brake, and you cant buy secondaries for a
US Zuma anyhow.

Clutch, belts, vario, crank, primaries are all out of an Aerox50. I own an OR, so I DO know what parts are correct.

[Ndog1]

I am pretty sure that I have the correct OR. The us new bugeye zuma is supposed to be like the Jog R. My kit is for a long case design. The vino is the other kit and has a short case i think.

Ndog

2000 SR racing LC TP 19mm delorto 65mph (stock gears)
2004 Super Zuma TP reamed cylinder 24mm flatslide
2004 Zuma Corsa/r 19mm arreche gianelli shot, 2005 OR ?

[zumasterling]

Doesn't the rear of an aerox have disk brakes? The wheel would probably be different as far as mounting goes.

[Crazy Scooter]

Well i don't want to argue but the jog r is an LC motor and as I recall Jered did mention in many previous posts that Jog Z (AC) parts fit the Zuma. Maybe the only difference between the kits it a different length belt due to the case length but I don't know on that one. Regarding the rear wheel, yes the newer models have a disc brake and the splines of the discs hub are smaller therefor do not fit, earlier aerox 50's used drum brakes as do all the Aerox 100's and the US Zuma. Funny thing is, the diameter of the actual tires on the Zuma, New Aerox 50 and the Aerox 100 are the same so if the case was shorter as you said the wheel wouldn't fit.... but on the older aerox's and bws they used a smaller diameter tire and rim which would explain the shorter cases bc of the smaller tire.
Anyway, good luck on the install and I hope it works out for you.