2005 Yamaha BWS (#2): Strip Down & Rear Lighting

Nadia's scooter (pictured above), just doesn't have the pep it once had. It's a 2005 Yamaha Zuma (YM50, same as mine) with the stock 50cc engine still in it. While it's been a great learner scooter, the 50cc engine just isn't giving the same power it once was (Nadia's words, not mine). With those words in mind, I felt it was time to give this scooter a little power increase and slight beauty makeover. 

Since I've already detailed much of the transformations I'm planning on doing with this scooter on my scooter, I'll dispense with the extensive write up, and proceed straight to the pictures.

(minor cracks to the fairing, and scratches will be addressed)

(passenger foot rest damaged)

(not visible, but rack bolts sheered)

(Turn signals to be integrated with tail light, license plate area to be shaved down)


Disassembly

(Sheered screw holder on the inside of fairing) 

(used JB Plastic Weld to re-secure the fastener area, worked quite well)

  Rear Lights

(Marked out where the LEDS would mount)

(same as above picture, but other side)

(Hole drilled out)

(LED's mounted)

(Rear lights completed)

2005 Yamaha BWS: Update. Finished

Finally, my 2005 Yamaha BWS is running insured, and on the road!

I would have loved to document more of the engine overhaul, however this website wasn't co-operating during the rebuild, and I didn't document anything. 

Cosmetically you can see the difference from a stock 2005 BWS (Blue), to my mine. The rear fender has been hacked, front fender removed, wheels pasti-dipped, and all the fairings painted and polished to match original color, and the addition of front LED side markers.

Engine upgrades included a 70cc big block kit (Airsal), 17mm Arreche carburetor (upjetted), Doppler intake, Malossi reeds & cage, aftermarket air filter. Everything went together rather smoothly, with the exception of the Doppler intake which seemed to push the carburetor out of position. With the Doppler intake I could no longer use the stock air box as it would not line up properly. I had no choice but to replace the stock air box with an aftermarket air filter.

On the exhaust side the Doppler pipe I ordered, specifically for this build, didn't fit. I had to substitute a Leo Vince.

In the transmission I replaced the rollers with the Doppler ones that were packaged with the aftermarket pipe. I installed a Malossi delta clutch and Malossi torque spring.

While it's not my fastest build, it easily keeps up to city traffic, and is much smoother.

My take away from doing this build, is DO NOT BUY DOPPLER PARTS!!!!

Stick with brands like Stage6, Malossi, and Athena when possible.

2005 Yamaha BWS: Taillight & Turn Signals

Following up on the documenting of my front fairing mods, this entry brings you my modifications to the rear taillight and turn signal indicators. I was hoping to replicate something similar to the photo below, which sell at scootertuning.ca for $79.99 (CAD).

2005 Yamaha BWS: Front Fairing

It's been over a year since I've posted an update about my 2005 Yamaha BWS rebuild. 

(image stolen from www, might have been my scooter)

My build is nothing like reality TV, where customized rebuilds are completed in weeks. There are many factors that have resulted in my build posts to taking so long, the most serious issue has been my inability to post to BLOGGER (which has been documented before). Other factors, like the cold weather, a cold workshop, postal shipping delays, and the whole trial and error process have added to this lengthy build. Finally there are all the problems I've been plagued with during this build. It's also a bit surprising that, parts for this model of scooter are harder to find, considering that it's a newer model.

Now on to the actual build...

2005 Yamaha BWS: Strip Down

Just a little update on the Bug-eye's current state and condition. It's sitting in the garage being slowly disassembled. Most of the rear end has been removed, beginning with the seat, fairings, tail light, turn signals, wheel, and engine.  

I ran into issues removing the front fairings which I will document in an upcoming post. Until then I hope these pictures will tie all of you over until then.

2005 Yamaha BWS: Introduction

While surfing Craigslist, I came across a post for a 2005 Yamaha BWS YW50 scooter a.k.a. The Bug-Eye (They are called bug-eye because the headlights resemble the eyes of a bug). The seller was asking $600 as-is, since he was certain that he had blown the engine. Even with a blown engine, at $600 this was a rather good deal. I already own a highly tuned 2001 Yamaha BWS CW50 (Pre-Bug) and have always hoped to get my hands on a Bug-Eye. Why do I want a Bug-Eye so bad...

Well the 2005 and newer Yamaha BWS scooters have a much beefier front suspension, a slightly wider stance, and far better gearing for in city driving. So I contacted the seller to make an offer only to be told that the scooter was already SOLD. Oh, the highs and lows that come from scavenging through Craigslist.

The next day, I get a call from the scooter owner informing me that his previous deal didn't go through, and the scooter was still available if I still wanted it. So I borrowed my brother, and his pickup truck, and went to see this scooter. From its appearance the scooter was in quite good shape, but there was definitely some engine troubles. While I tried to gauge how severely damaged this engine was, without dismantling it for proper inspection, it would be all hypothetical. I tried haggling, but this seller stayed firm on his price, so I decided to take the gamble and buy the scooter anyways.

Unfortunately do to an issue with an corrupt memory card, I don't have any pictures of the scooter when I purchased it, which totally sucks. All the pictures in this post are not of my scooter but pictures of scooters that look almost identical.

First thing I needed to do after getting the scooter home, was finding room for it in the garage. Now i had to determine how much damage had been done to the engine. Typically by removing a few parts I could have access to the engine, but since I already knew I would be fully modifying this scooter, I stripped it right down.

Check in on my next post when I document the tear-down process.