Dr180 Kit

[Philbutt]

Right, I've got a DR 180 kit and a new 102 jet, going to be putting this on over the weekend. So anyone know whether i need to mod the air filter at all to increase the air flow. I've seen somewhere about drilling the underside of the filter but can't remember where. Following advice from DR at the mo and leaving my standard exhaust on to see how we do. Also can the head and cylinder be removed from the unit in situ or does the whole back end need to come off. any tips and hints would be appreciated. The kiy looks pretty good quality

[GLscoot]

Dont know about the air filter. Yes you can fit the cylinder kit with the engine in the frame.
remove exhaust and flywheel (not compulsory but gives you more room)
undo m7 nuts diagonally ( i replace the studs, nuts & washers, not compulsory)
as you are replacing everything the hardest part will be removing the cir clip on the inside, so make sure you fit that first before fitting new piston
mark the two pins on the piston with a marker pen and a direction arrow on the piston head, make sure you fit the piston correctly, arrow points to the exhaust and the pins for the rings point upwards.
give the new barrel a good coat of oil, this helps when fitting the barrel to the piston.
either use grease or gasket paste to stick the gasket to the barrel, dont push the barrel all the way into the engine leave around 5-10mm then fit the new studs, by leaving the barrel out slightly will give you a view of the stud holes on the engine.
when all the studs are in a bead of gasket paste on the cylinder head, fit and tighten diagonally, very important with the DR kit the head is a very tight fit. You can pin down some wet'n'dry to a table little oil and rub the face of the cylinder head in a circular motion.
i think thats everything, if not someone will post what i have missed.
Make sure you run it in 400miles at no more than 3/4 throttle.

[Philbutt]

Cheers. Every bit of info helps.

[goldeneye]

get a bigger main jet than a 102, or itll gan bang.

[gaz_powell]

filter alterations

http://www.vespalabs.org/index.php?titl ... ght=filter

make sure you go further up on the main jet if you do the modification

best of luck

Gaz

[shocky]

I just had a cylinder rebored and should be fiting it this weekend ill look and see what jet i have in mine im sure i have a 20 mm carb though mine has pulled 60 on gps before and it was pretty worn on the rings im not hoping for much more agenuine 55 cruising speed is all im after

[goldeneye]

last one I ran , as a daily work scoot , ran something like 140/be4/115----55/160 pilot on the 20mm carb,drilled filter, with 22 tooth clutch and a sito plus exhaust. 3% cheapo oil. great allrounder, cheap to build and run , woud do an easy 65 on the clock and pulled great. did just over 100 miles to the standard tank. a word of warning, get the barrel honed out before fitting , they are very tight from new, or you will be running in for a long time.

[shamrockexpress]

I,m going to fit one of these kits with a sterling exhaust , std casings and crank i have dellorto 24g and 24e carbs what oune would you fit?
thanx in advance.

[Philbutt]

Right then, the kits on with a 102 jet, and after I worked out the fuel tap should be on it's kicked over a treat, idles nicely and has got some go in her know. I'm being told by various folks that I need a bigger jet than the 102 I was given by the Scooter service centre I got the kit from. I'm using a standard exhaust for now which is recommended by the supplier. Also going to be changing the plug to a B7HS. What's the worst than can happen if I leave the 102 jet in.

[shocky]

Worst is a hole in piston and all the crap goes in the crank and around the sealing pad and locks up you skid come off and die or are seriously injured or you kill or injure someone else I wouldnt risk it on less than a 110 jet with standard pipe