46 mm Puch Airsal review

First impression: ahahaha, this thing rips ahahhhahaha. A few times I wondered what I was doing going so fast on a bike this small. Seriously, it took the biggest hills, known to bog down cars, and was accelerating (my version of breakin, yep). Didnt struggle once, not even a little. Ive ridden two pretty built tomos a35s up the same hills and they bogged like crazy without a huge head start (one tomos was airsal built the other Kstar). My friends variated polini built tfr has problems there. I still have a grin on my face.

Technical: the kit is not a complete bolton, although you dont "have" to cut the case, you might want to port match =). The transfer ports are good deal bigger then stock though not too crazy like some other kits, The intake port is slightly over 20mm, I used a 21mm black treats intake and 21mm phbg. For the pipe I used a boss, the header is very close in diameter to the exhaust port (huge).

Grind: The exhaust studs and the intake studs are slightly further apart then stock, I had to widen the bolt holes on both the pipe and the intake for them to fit (make the holes oval towars the outside). The pipe rear mount didnt lign up so I had to cut it a bit as well. Then there is the gasket thing, gaskets that come with the kit are shit except for the metal head gasket. I ordered the treats 70cc gasket set in advance to have spares and was happy about it. With the kit cylinder gasket and one head gasket the piston was hitting the head, I had to trim the cylinder hasket and the head gasket from the treat gasket kit to fit the larger kit... The only way my piston cleared completely was with the thicker cylinder gasket and two metal head gaskets.

Carb: I used 21mm del phbg, 50 idle jet, 85 main jet and w7 needle on 2nd down from the top. My low low end blows (takeoff), hard to start and wont idle yet. Seems like the idle jet is too big and the needle needs a little tuning. But as soon as it gets going 5mph its game on!

Tommorow Ill try to adjust the carb and get the thing to idle, maybe get that 0-5mph reasonable, Ill try to keep this post updated. Ran it hard for 20+ min and it didnt blow up or seize yet, thats good news right...

Re: 46 mm Puch Airsal review

Dropped the idle jet to 45 today and upped the main to 90, starts much better and idles somewhat. I think it needs closer to 40 on the idle jet. The 90 main is nice but it seems like there was more top end with the 85, Ill switch out again to test some more.

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Alright, so this is the setup so far, 40 idle, 85 main and a w9 needle clip at the top. It idles and doesnt bog any more but its still a bit hard to start. I cant believe 40 idle may be too much still. Going to open it up through town and see how it does. Btw, the Boss is the best sounding pipe Ive heard so far.

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I just ordered this kit and am glad to hear a review on it so soon. I'm going to be running the same setup, not the same intake because treats was out.

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Two things, I cant decide if the w7 or w9 needle is better, they are close but the w7 seems a little faster through the low end. Maybe some other needle would be best, Im still trying to figure out what I need. Also today the clutch went out on me, I haven't opened it up yet but my guess is the clutch nut came off. Put lots of torque on it when installing the clutch, use locktite and a lock washer if there is space for one... Im using a treats clutch pack btw.

Re: 46 mm Puch Airsal review

If you run a w9... you need leaner jet.. you run a w7 .. you need a fatter jet ..

I just forget how it goes.. good luck tho

Re: 46 mm Puch Airsal review

Ok, so, the metal head gasket that comes with the 70cc gasket kit is shit. For some reason they put a 5th hole into it making that part of the gasket very weak. Not sure what that hole is for but it blew out today and took the other gasket with it. If anybody is using this kit and the piston does not clear the head with the single head gasket, go get a piece of aluminum twice as thick and custom make a head gasket... This kit has some crazy high compression.

On the other note, the clutch nut came loose from all the torque, I put it back on with a lock washer, locktite and some serious torque. Shouldnt come off again...

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IRE Beth and I just put one of these together over the course of a couple days.. This kit really does have some crazy compression ratio.

She blew her head gasket out in less than 5 miles. Seriously.

I don't know what were taking for the next step. To limp it around probably just put another kstar 70cc head gasket in there, then keep looking into making one out of a stronger or slightly thicker material.

Let me see if I follow what you did...

recut a new base gasket with thicker material

used 2 head gaskets

blew one out

went with a thicker aluminum hand made head gasket?

Re: 46 mm Puch Airsal review

***VANILLA BLUNDER*** /

more base gaskets, less head gasket. waste of time

Re: 46 mm Puch Airsal review

agreed.

also, use the choke for a cold start.

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A w9 is just a fatter/leaner needle right? Why would you necessarily need a leaner jet to run a W9?

Re: 46 mm Puch Airsal review

I.R.E. Tom, yeah thats pretty much what I did and then some. The piston didnt clear the head with the kit base gasket and the kit head gasket. I trimmed the base gasket from the 70cc kit and put that in, the piston still hit the head. So then I trimmed the head gasket from the 70cc kit and installed that, piston cleared. I also tightened the head on with a flat washer followed by lock washer followed by nut with locktite to keep the it on and seal tight. Used a flat washer and a lock washer on the clutch to keep that from coming off (treats clutch no woodruff key). This kit wants to tare the bike apart, it is angry.

Then I went and got a piece of high grade aluminum twice as thick as the kit head gasket and carved out a custom one, seems to work great.

Re: 46 mm Puch Airsal review

Ok, just so i have this straight. This is a 70, 72, or 80cc kit. Teats calls this an 80, but 80s won't fit on the bottom end without boring, and it is spensive as hell there now. Hmmm, I am aware of the 72cc ("biggest that will fit kit"). I do appreciate the review, I'm sure this kit rips.

How does this compare to the 70cc, 45mm Puch kit for power?

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it's because the cylinder skirt is super thin, where the other kits are thicker... Same OD, bigger ID...

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^^^ is right, the cylinder sleeve is very thin so you have to take care installing the kit BUT it seems to move heat around much easier because of it. It also has some very large fins. Overall the kit stays much cooler then any other Ive tried. As far as power goes, compared to the regular puch and even tomos reedvalve 45mm airsal/treats kits, its in a whole new league. Trabsfers, cooling, timing, intake and exhaust ports are all much better. If you dont want to weld the case this is probably the best puch kit out there.

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Looks awesome. If I didn't have a Destroyer already made for a slanted exhaust port, I would probably be inclined to get one of these...

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Trying to post a pic:

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Re: 46 mm Puch Airsal review

Why wont it show html pic post?

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photos go like this...

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I am really impressed with this kit. it's basically a 72cc cylinder, 46mm bore.

we had to grind the case a bit to make the sleeve fit, actually. just a hair all around though.

Re: 46 mm Puch Airsal review

Alright, so would it be advisable to go the approach like the MK65, where you create an aluminum shim for the base to cylinder to make the difference when the piston is hitting the head?

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IMGhttp://i235.photobucket.com/albums/ee5/vladcorp/engineside.jpg

Re: 46 mm Puch Airsal review

FAIL.

Re: 46 mm Puch Airsal review

GARzan Justin /

^Maybe?

Re: 46 mm Puch Airsal review

GARzan Justin /

Woo!

Re: 46 mm Puch Airsal review

GARzan Justin /

You should send me a cookie for that.

P.S. - sorry thread viewers, it's huge.

Re: 46 mm Puch Airsal review

Can you post the code like "" code "" or something. I failed way too many times...

Re: 46 mm Puch Airsal review

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