If I had to do it over again I would go with the Mikuni 32mm flatslide carb TM321, Dennis Kirk #1660 for 151.99 or the Mikuni 32mm roundslide carb VM3233, Dennis Kirk #16464 for 93.99. It's all up to preference on which style you want. You can get an aftermarket thumb throttle and cable that will work. I just went the cheap way and got the twist throttle kit. I do prefer it over the thumb throttle too. As far as the jetting on the 32mm I'm not sure what you would need. The flatslide carb comes with a 250 main jet and the roundslide carb comes with a 200 main jet. These may bolt on and work perfectly or may need to be changed. You'll have to run the motor and check what the plug looks like to determine the jetting. Jets can be purchased at just about any motorcycle, dirt bike or atv dealer.

As for the CVT weights, there are several kits out there that will work on these drives. Just do a search on Honda Helix, Reflex or Big Ruckus. Make sure it is the model with the 249cc engine not the 244cc, though the drive systems are probably the same. One mod that I have read about involves removing the lighter 3 out of the 6 roller weights ( I believe it is the lighter,gray ones). I'm not sure if the Falcon has all 6 in to begin with or if they are even the stock Honda colors. You can even buy just the rollers and or stiffer springs for these. If I find the site again I'll post it here.

i8amm

 

Here are some web sites for info. The last is one of a few for performance parts and has some information on it as well.

http://www3.telus.net/dougsimpson/frank.html

http://scootertrip.com/reflex/FAQ/koehler/VPT.pdf

http://www3.telus.net/dougsimpson/Elite_4.html

http://www.beedspeed.com/

i8amm

 

Sir,
You are the man. I know you love ole SEADAWG[img]i/expressions/face-icon-small-smile.gif[/img] I'll keep you posted...thanks for the help, again[img]i/expressions/face-icon-small-smile.gif[/img] SEADAWG OUT!

 

Seadawg,

I have been doing some more investigating and have found that a company called Malossi makes a performance camshaft for the Honda motor and a aluminum cylinder kit as well. Not to mention several CVT parts/kits. I also noticed, while re-reading some of the links I posted, that one site does mention using the 34mm mikuni. If you were to order the 34mm flatslide and a 210 jet you would pretty much have what I do now. You may also want to get a 200 and/or 195 jet as well.

Have you modified you muffler yet. I got a great deal of performance gain after I modified mine. Even before the carb replacement. Another note, should you want to improve the front end, a set of honda 400ex front springs will fit directly onto the stock shocks and make a big difference. Since the honda rear is link type the spring will be too stiff. I just got a Raptor 660 rear shock/spring and linkage and will eventually get around to trying to mount it on my falcon to improve the rear handling. I may have to make a new swingarm or modify the old one (lengthen it) to make it work. The stock spring/shock works good in the lightest position for trail riding but seems to bottom out on the slightest of jumps or bumps. Three notches or more up works good for small jumps and bumps but is a kidney buster while trail riding and getting to the jumps.

If you find anything out regarding the cdi unit I'd appreciate knowing about it. Perhaps your mechanic (if he knows a lot about these things) may know something. I may get an extra cdi unit and try to figure out the circuitry. It's probably nothing more than swapping out a fixed resistor for one of a different value or replacing it with a variable resistor to fine tune the high rpm's.

That's all for now. If I think of or find out anything else I'll make another post

i8amm

 

This is another of several sites that I found that will give some insight to the CVT drive and some mods. Just look in the stock modifications and check out the which mod first, variator spacing and spacer shortening subjects first. Look around at other things like performance modifications and tuning as well.

I took my variator apart tonight and checked it out. I found that you can shave a little bit off the spacer but not much. I shaved a hair off in the lathe and cut a slight angle on the end so it would go back in the bushing smoother. I also polished it with some fine emory cloth while it was out. It was actually sticking inside the variator. There was no lube on it at all. But there was a lot of grease on the variator rollers which, according to all the postings I've been reading, shouldn't be there. I cleaned off all the grease and put a very light coating of white lubriplate on the rollers to help them move. I then put as much lubriplate on the engine shaft, bushing and spacer as I could. Re-installed it, cleaing all the excess grease off the outside and using blue lubriplate on the nut. (This nut had come off on me a week or two ago, stranding me in the trails) I took the clutch assembly off and cleaned all the dust out of it. Couldn't find any issues with it except for no grease on the needle bearing and inside the rear shaft hole between the needle bearing and sealed bearing. I put some white lubriplate grease in this area as well.

You'll need to use an impact wrench/gun to remove the nuts on the variator and clutch assembly. You won't be able to do it without damaging the fins on the variator or busting your knuckles trying to get the clutch nut loose.

There is a ton of information and parts we can get for the Falcon engines that are available through these scooter sites. Wrote down the belt number for the Falcon 250, Goodyear Powerlink 828 22.5, should someone need this number and not have it already. I'm still looking for an aftermarket CDI box. The cheapest one I've found so far is $65 with free shipping but I'm not sure if it has an advanced curve written to it. It says it has no rev limiter.

I'm guessing I'll only gain 1 to 2mph from what I took off the spacer. I will probably gain a whole lot more by lubricating the spacer and bushing. I'm sure the variator wasn't moving freely. It took some work to get the spacer out of the bushing the last 1/2 inch or so. There was a lot of what looked like burnt grease on it. Probably the minute amount they put on it burned up right away. The variator rollers all felt to be the same weight. I have no scale but used a digital vernier and checked the thickness of all of them. They were all pretty close (between .08 of each other from highest to lowest thickness) One thing you may want to try is removing 3 of the 6 rollers and see what happens. I've read about this being done. I'm not too worried about playing with this yet since the only issue I have is the engine running out of revs when I try to go to top speed. I have some throttle left but I lose acceleration. I figure getting rid of the rev limiter and putting a 1 or 2 tooth smaller rear sprocket on may help.

i8amm


http://battlescooter.proboards27.com/

 

An update on the CDI unit for the Falcon 250. I found the manufacturer and a diagram but I don't read chinese and I'm not an electronics genius. If anyone out there can do either, both or knows someone that can do this show them the diagram and see if they can figure out which wire is for the ever-rev circuit and if disconnecting it would disable the over-rev function. I'm going to continue looking for an aftermarket unit that would advance the spark a bit and elimiate the over-rev function.

http://www.sanxin.com.cn/en/Exhibit/exhview.asp?pid=15

i8amm

 

Any updates on the Kazuma 250 guys? I got mine running much better...still waiting on the new carb as posted. However, I was our there, my chain tensioner popped off and wore a hole in the frame. I can patch it, just hope I get through the bugs.

 

the roller weights stock on the the 250 is 23.5x18mm 21grs, for best performance for this engine is 23x18mm 15grs, the best roller weights are dr pully's and are sliders not rollers, these weights not only improve low end but will also increase top speed by appox 1.3 mph. these weights cost around $30 as far the carburetor i have a mikuni 30mm carb kit for the 250 kazuma,redcat, ect, any of the 250 water cooled with the cvt transmission, the kit includes the prejetted mikuni carb,spacer,throttle cable,k&n air filter,intake gasket,. if interest you can pm me. one thing to note here the only thing this caburetor will do is increase thottle response and not performance, the stock carb is a 30mm kehien so their won't be any performance advantage

 

iam8/Bill
I got the carb, but Dennis Kirk can't tell me what throttle cable or twist kit to buy that will work with the new carb. I got the VM3233 Dennis Kirk 16464??? Can you tell me what part number for the throttle/cable kit you bought. SEADAWG

 

i8amm,
Any help on that throttle assembly you bought for that carb will be appreciated. I can't PM you for some reason. Dennis Kirk can't tell me which one goes with that Mikuni 32 mm carb. Help. SEADAWG