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Shot Caller
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 Post subject: ZuZoomer Stock Build
PostPosted: Sun Jul 08, 2012 7:29 am 
My Wife's Zoomer. Just bought it for her birthday. She's loving the fact that it's a 'Rescue'. A Yellow '06 EFi Zoomer. Stolen-recovered Cat C Insurance write-off. Picked it up for a decent price in 'almost' repaired state. Starts every time and rides and stops great, luckily most damage was cosmetic. 13k on relatively new tyres. It'll be staying stock but will need some TLC and is set to change colour in the future:

Essential mods for daily riding so far include:

(Updated Nov '13)

Malossi Variator with Dr. P's.
Polini Intake Manifold
Custom K&N Panelled Airbox
Polini Kevlar Belt
NCY Front Shocks
Kitaco B250A Rear Shock
Stubby Indicators with Battlescooter Lenses
Maxxis Rubber
Buzetti Kickstand
BMX Pegs
Custom Schwinn Buddy Seat/Rear Carrier for riding 2 up or OEM Backrest if needed.
Black Stock Seat Frame with OEM Grills
Black Battery Box
Tucano Urbano R151 and Bar Mitts.
KCP Frame Caps and Bar Ends
Oxford Heated Grips
Chase Harper Underseat Bag
Probolt bits.
Plenty of Security.


Image

Image

Backrest, Rear Carrier and Basket came with it:

Image

It has a brand new Yellow Battery box but requires an ignition cylinder cover:

Image

Worst damage is the bent bars where some tink tried to break the steering lock, mirrors are gone but I'll put my Stockers on it:

Image

I'll be picking it up later this week and this thread will document it's quest to return to the road. V5'll be here in 4 weeks so have to prepare it for MOT.
A lot of stock stuff I've pulled off my Zoomer will be whacked on this so managed to save a bit there on odds and sods (Shock/Ign. Cylinder/FIlters/Plug). TR Peeps are in touch with Bars. Let's hope it all goes well and I haven't bought a Yellow Lemon! :)

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BLKNYLW Build Thread:
http://totalruckus.com/phpBB3/viewtopic.php?f=95&t=66177

ZuZoomer Rescue Build Thread:
http://totalruckus.com/phpBB3/viewtopic.php?f=96&t=71974


Last edited by rick_audible on Sat Nov 16, 2013 10:47 am, edited 5 times in total.

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Habitual Offender
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 Post subject: Re: ZuZoomer Stock Build
PostPosted: Thu Jul 12, 2012 1:18 pm 
Looks good


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Shot Caller
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 Post subject: Re: ZuZoomer Stock Build
PostPosted: Thu Jul 19, 2012 3:30 am 
Been working on it when I have a time since getting it Saturday. I'm surprised at how little has needed done so far. Immediately replaced the rusty rear shock and lock cover for my old stockers and switched the bars Zoomerdude dropped off for me then whacked a bow on it for 'presentation'.

Image

So far as well as the bars/shock I've given it a basic service, replaced the speedo cable, new front axle, new air filter in, couple of bulbs, whacked in a Malossi variator picked up from racingturtle (already has new belt) and will drop the oil etc today now that I have o-rings etc. There were some wood screws holding the battery box on and a rusty ducktail bolt but threads were fine so replaced them just to be anal. The Crankcase seal is a bit mouldy so I'll pick one up from Hartgate later. Tyres are relatively new and brake wear markers are well away from each other so should breeze MOT once I replace headlight bulb. L plates and oil if the rain holds out then I'll take some pics.

_________________
BLKNYLW Build Thread:
http://totalruckus.com/phpBB3/viewtopic.php?f=95&t=66177

ZuZoomer Rescue Build Thread:
http://totalruckus.com/phpBB3/viewtopic.php?f=96&t=71974


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Habitual Offender
Habitual Offender

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 Post subject: Re: ZuZoomer Stock Build
PostPosted: Thu Jul 19, 2012 4:06 am 
Lookin good mate
I could never get my girlfriend on one


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Shot Caller
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 Post subject: Re: ZuZoomer Stock Build
PostPosted: Thu Jul 19, 2012 6:32 am 
ucantcme wrote:
Lookin good mate
I could never get my girlfriend on one


Thanks Dude. I'd be scared to ride yours! Heard your pegs have messed you up a couple of times. I bought her it in the hope that she rides it enough to feel confident to drive a car on London roads. She's had mine away a couple of times as I forced her to take it but I can't always do without it. I won't have to pick her up from the Railway Station anymore. :D

About to drop the oil but got sidetracked with foot pegs. Having slashed my legs up plenty with my PWJDM's, I thought she'd appreciate fold-ups.

Image

_________________
BLKNYLW Build Thread:
http://totalruckus.com/phpBB3/viewtopic.php?f=95&t=66177

ZuZoomer Rescue Build Thread:
http://totalruckus.com/phpBB3/viewtopic.php?f=96&t=71974


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Shot Caller
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 Post subject: Re: ZuZoomer Stock Build
PostPosted: Sat Jul 21, 2012 8:45 am 
All done. Just mirrors to take from mine. £41.58 to service/sort everything and £30 on Variator. Pegs/Shock/Lock/Air Filter I had lying about.

Image

Image

Image

Image

Image

_________________
BLKNYLW Build Thread:
http://totalruckus.com/phpBB3/viewtopic.php?f=95&t=66177

ZuZoomer Rescue Build Thread:
http://totalruckus.com/phpBB3/viewtopic.php?f=96&t=71974


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Habitual Offender
Habitual Offender

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 Post subject: Re: ZuZoomer Stock Build
PostPosted: Sat Jul 21, 2012 9:04 am 
Get the wife out for a ride and we will meet up somewhere


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Shot Caller
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 Post subject: ZuZoomer Stock Build
PostPosted: Sat Jul 21, 2012 2:23 pm 
As soon as V5C arrives and it's MOT is done we'll be well up for a meet.

_________________
BLKNYLW Build Thread:
http://totalruckus.com/phpBB3/viewtopic.php?f=95&t=66177

ZuZoomer Rescue Build Thread:
http://totalruckus.com/phpBB3/viewtopic.php?f=96&t=71974


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Shot Caller
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 Post subject: ZuZoomer Stock Build
PostPosted: Thu Aug 16, 2012 12:19 pm 
V5C turned up. Got to keep 55 Reg. Took it for MOT but it failed for a hairline crack in the yoke, probably from when steering lock was busted. Didn't notice it at all. Has to be alloy-welded to get a pass. Managed to pick up a nail in back tyre en-route to Tooting. Not punctured though. :-(

Before:

Image

After, £40 lighter:

Image

Inside 14 days so free re-test. Passed MOT.

_________________
BLKNYLW Build Thread:
http://totalruckus.com/phpBB3/viewtopic.php?f=95&t=66177

ZuZoomer Rescue Build Thread:
http://totalruckus.com/phpBB3/viewtopic.php?f=96&t=71974


Last edited by rick_audible on Thu Sep 06, 2012 8:28 am, edited 2 times in total.

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Shot Caller
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 Post subject: Re: ZuZoomer Stock Build
PostPosted: Mon Aug 20, 2012 5:53 am 
Smartbobby furnished me with a stock black seat frame so chucked it on yesterday. Way better look than the yellow one and also meant I could dump the rear carrier. Covering paint chips was all that it was there for.

Image

_________________
BLKNYLW Build Thread:
http://totalruckus.com/phpBB3/viewtopic.php?f=95&t=66177

ZuZoomer Rescue Build Thread:
http://totalruckus.com/phpBB3/viewtopic.php?f=96&t=71974


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Shot Caller
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 Post subject: Re: ZuZoomer Stock Build
PostPosted: Wed Aug 29, 2012 2:02 pm 
She's now Taxed, Insured and MOT'd so officially on the road. Had a good ride out on her yesterday once she was fully legal. Got a new Polini Inlet for my Zoomer so will switch my old Polini inlet to hers and put fresh plates on now I have them. Bugs me to only hit 28mph on it even with Malossi so may address the rev. limit once the Mrs is more confident on it. Hoping airflow makes a difference. There seemed to be some filth in the inlet so may have been on it's side at some point. May explain it's lack of top end.

Old + new inlets:

Image

_________________
BLKNYLW Build Thread:
http://totalruckus.com/phpBB3/viewtopic.php?f=95&t=66177

ZuZoomer Rescue Build Thread:
http://totalruckus.com/phpBB3/viewtopic.php?f=96&t=71974


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Shot Caller
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Posts: 1033
Location: London
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 Post subject: Re: ZuZoomer Stock Build
PostPosted: Sun Sep 02, 2012 11:54 am 
After having a scan through the forum I found a thread mentioning a 'Washer' that comes with the Malossi Variator. Picked up a used one but didn't get any washers with it so after a bit of searching I've ordered the 2 spacers at the link from the Malossi site. Lucky they sell spares. £7 may get me another 7mph.

http://www.malossistore.co.uk/Prodotto. ... re=5111852

Decided to reupholster the backrest cushion with a section of the stock seat cover. Didn't do too bad a job. Why Honda couldn't do it in the first place is beyond me. Buddy seat next but may get that done professionally.

Image

_________________
BLKNYLW Build Thread:
http://totalruckus.com/phpBB3/viewtopic.php?f=95&t=66177

ZuZoomer Rescue Build Thread:
http://totalruckus.com/phpBB3/viewtopic.php?f=96&t=71974


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Junior Mint
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 Post subject: Re: ZuZoomer Stock Build
PostPosted: Fri Sep 14, 2012 12:35 pm 
rick_audible wrote:
After having a scan through the forum I found a thread mentioning a 'Washer' that comes with the Malossi Variator. Picked up a used one but didn't get any washers with it so after a bit of searching I've ordered the 2 spacers at the link from the Malossi site. Lucky they sell spares. £7 may get me another 7mph.

http://www.malossistore.co.uk/Prodotto. ... re=5111852
Your wife will hate you! The ring in your link is not the notorious washer, it is the plastic speed limiting spacer that everyone throws away when they mount their variators. The washer needed is a thin metal one that sits right on the axle. You put it on the axle before you remount the variator assembly. It is because the Malossi kit is just a little bit thinner than stock.


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Shot Caller
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 Post subject: ZuZoomer Stock Build
PostPosted: Mon Sep 17, 2012 1:47 am 
She'll live. Got them both coming. I figured one of them would be useless. 'Limiter' kinda gave it away and it looks to be keeping faces apart but without knowing what you just enlightened me to I had to order both. Postage was the same.

All I had to go on was this and I didn't have #'s 1 & 7.

Image

_________________
BLKNYLW Build Thread:
http://totalruckus.com/phpBB3/viewtopic.php?f=95&t=66177

ZuZoomer Rescue Build Thread:
http://totalruckus.com/phpBB3/viewtopic.php?f=96&t=71974


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Junior Mint
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 Post subject: Re: ZuZoomer Stock Build
PostPosted: Mon Sep 17, 2012 4:09 am 
Good! It's the part #1 you might need. Note, the stock boss and the Malossi boss is slightly different in length. And in some cases in diameter. Just make sure the inner half of the belt pulley runs free and smooth on the boss. I have noticed in a couple of cases that the boss supplied with the variator is too thick which makes it useless. Stock boss and washer takes care of that.


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