Port Mapping

ZXI Rear Cylinder

Middle Cylinder to check they are the same, and they are:

Start Stop Switch Issues

Need to find out the manufacturer of the actual switches inside the Stop Start switch. Tether is unreliable:

Starting to understand the stop start switches. Working on Pat's 1100 Standup switch:

These contacts:

Touch the washer in the switch barrel:

Stretching the spring so that it may prevent it cutting out. It cuts out every now and then and playing with the switch seems to cure it:

After the first weekend of riding

Held up well, except we didn't have the top bracket for the E-Box and it shook loose.

Water Routing Work

Getting ADA Head Ready

ADA Head and 26cc domes:

Starting to Figure Out Water Routing

E-Box Start Stop Switch

Need to connect a SXR Start Stop Switch into the ZXI E-Box. Cut the connections off.

Red-Black from the CDI, not needed, cap off. 

Red from regulator to Stop/Start Red-Blue.

Yellow-Red to Yellow-Red on Stop/Start

Black to Black

White from CDI to White on Stop/Start

Done with the inside of the E-Box.

Getting Carbs and Top of the Motor Ready

Torquing head bolts to 21 ft/lbs.

Cutting Hole for Bilge

Starting E-Box Conversion

Red with Yellow, not needed, Black with Yellow not needed:

Grey not needed, Black with White, not needed.

Yellow with Black not needed. Blue with Red splice to Blue with White:

Pressing in new mid shaft

New Bendix

Donor motor needed a new Bendix. They are available on EBay for about $35.

Setting the Motor in to measure mid shaft position

Need to press out the Yahmaha mid shaft and replace it with the shorter shaft.

Some Pieces

Motor mount plate fabricated to mount ZXI 1100 Motor in the Blaster

Need to convert the Yahmaha couple to the Kawaski coupler.

Need the shaft to stick out the back 19.5 to 20.5mm.

Old Motor Out