ZX Transmission/Belt Swap

Wheelman-111 · Post by **Wheelman-111** » Sat May 02, 2009 8:12 am

Greetings:

Stock pulleys and belt in SE/05 and SA/16 produce a 2.4:1 belt reduction, according to the Service Manual. With taller aftermarket gearing, this results in a second-gear start effect. Many compensate with a beefier clutch and sky-high launch RPMs, but that only increases the stress on the driven pulleys, which are not designed for more than 5HP and a geezerly riding style.

The Ruckus front pulley and the ZX rear pulley (with its infamous 3-pin Torque Driver - Wow!) are both larger than stock, creating some interesting possibilities. How have the Cognisenti adapted these to their Elites?

A step-through including what/where to buy and installation would deserve immortality in Technical Documents, IMO. If you show pics, I'll talk to the Pope about a Sainthood.

WHAC prays to Saint Scooter every night for a better tomorrow.

evilone · Post by **evilone** » Sat May 02, 2009 6:54 pm

Anyone correct me if i'm wrong.

Kymco people 50 or agility pulleys which are the same as zx with 3 pins

zx bando belt from vtcycles listed under 91-95 super dio

Kymco Scooter clutch boss (the un-restricted version) from http://www.scootertherapy.com/ $26 plus s+h

evilone · Post by **evilone** » Sat May 02, 2009 6:58 pm

Now what all would i need for the rear?

evilone · Post by **evilone** » Sat May 02, 2009 7:32 pm

Looks like the jog is a maybe too. I don't know why but i thought i'd look at the jog vs. elite. 1st pic shows pulley size difference. 2nd pic shows elite drive plate assembly sitting on jog drive plate assembly, looks so close? Curious what the kymco pulleys measure before i try the jog clutch. Maybe i'll just order the new kymco parts. Blurry!

burnt_toast · Post by **burnt_toast** » Sat May 02, 2009 9:54 pm

I was going to wait until I did more testing, but what the * looks like yall are eager to find out if this works.
This is the kymco pulley test fit pics

Wheelman-111 · Post by **Wheelman-111** » Mon May 04, 2009 4:38 pm

Greetings:

So the shaft diamters are the same? I figure a bigger rear pulley will require a longer belt. This in turn will require a bigger front pulley as well. Otherwise the belt can't travel all the way to the top at both low and high-rpm situations. Your thoughts and measurements welcome.

If you add descriptions to tell us what we're looking at, Benny says you're in. How does Saint Burnt of Bexar sound?

Wheelman-111 · Post by **Wheelman-111** » Mon May 04, 2009 9:11 pm

Greetings:

POLINI variator arrived with Polini Kevlar belt. The vario pulley is as big as it can be and still clear the starter housing, and the belt is a 655mm x 15. Stock is 641mm, I believe.

Performance through the midrange with 6.3 grams is flawless but there's a But. There's always a big But.

Fully closed, the driven pulleys don't pull the front of the longer belt all the way to center at the front pulley. This means the takeoff struggles with something less than the 2.4:1 belt ratio, which is already tall for Flash's 65cc fighting 7.83:1 gears.

The solution would seem to be the larger rear pulleys we've been discussing.

Where/how can I score a set of those again?

z50r-ghost · Post by **z50r-ghost** » Tue May 05, 2009 12:22 am

mr. toast,

Here's some info that you will be needing to do the complete ZX swap:

For the DIO ZX drive boss, the Sym DD50 drive boss is EXACTLY the same and easier to find; it's 1.5 inches long.

You will have to use a wider drive belt due to the drive boss.
DIO ZX drive belt size: 654 x 18 x 30

You will have to use a dremel tool / die grinder to remove a SMALL amount of the case / belt housing, or the drive belt will end up rubbing and it will break. Let me know and i will take pictures of the places you will have to sand down. Its painless....

While you are doing your mod, you might as well purchase a torque-driver plate, which has the "trenches" or pin-slots cut at a much better angle for acceleration. Some torque drivers have 2 different sets of trenches, one set for acceleration, one set that is stock.

Here's a link:

http://cgi.ebay.com/ebaymotors/adjustab ... 27011r8066

i also added a Koso CNC drive face, an SEF ramp plate, Koso variator, Polini roller weights, a Stage 6 RT racing centrifugal clutch, a Stage 6 1500 RPM spring, and a Malossi "Torsion Ring" which helps reduce the twisting stress on the rear spring.

Hope this helps - keep us posted... jc

evilone · Post by **evilone** » Tue May 05, 2009 6:25 am

Do you have to call Roselle imports for the Malossi torsion controllers? I've emailed twice with no reply.

burnt_toast · Post by **burnt_toast** » Wed May 06, 2009 8:33 pm

The power is in your hands now evilone, good luck on your pulley journey

evilone · Post by **evilone** » Wed May 06, 2009 9:00 pm

z50r-ghost · Post by **z50r-ghost** » Wed May 06, 2009 11:18 pm

evilone,

i got my Malossi Torsion Control from scootercraft.com - i think is was about $6.00

i TOTALLY can recommend scootercraft.com; they are in Canada and have a great selection, good prices and freaking fast shipping.

i have ordered from them about 5 times now w' no probs whatsoever.

later man, good luck with your trans swap.

jc

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ZX Transmission/Belt Swap

ZX Transmission/Belt Swap

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