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Thanks for the reply. As per my post timing and clearances have been done (twice actually) and I am pretty sure they are right. I'd probably put my money on it not being a carb problem either, the pilot jet works ok when idling and revving it up at a standstill and the "stalling" feels like...

Hi guys, I've acquired a DHZ 160cc which is the same as a PitsterPro(?) I believe. Its got what I think is the Z155HO motor (possibly Z160HO I guess but its a few years old so I assume its the 155). It starts easily, it revs up in neutral or in gear with the clutch in...all seems fine...

Yep, you're right again I had the mixture slightly out. Spent a good portion of the weekend tidying it up, looks and goes awesome now, will have to post a pic. Only thing left to do is mount the oil cooler. So far all the lights etc seem to work OK; the motor outputs 70w and I'm not exceeding...

Have ordered a manifold spinner (love that idea) and also a #38 slow jet as it has the hesitation as you suggested. Rode to work today, goes like a champ and I'm really happy. Still won't idle but I will hopefully find out more this weekend, I partially fixed it (throttle cable was too tight...

Hey. Thanks for all the info above! I really appreciate it especially the manifold pics, I will definitely be doing that to bring the angle from the frame out a little more. I don't get much time during the week to work on it, but I've had it running last two nights for a short time. Can't...

Thanks for advice - have had a busy day! Almost got the bike idling well now, haven't had it out for a little ride yet but it's getting close! Do you see this as an issue (lack of plastic spacer between manifold and head). The corner of the carb is touching the frame as is, so I can't fit a...

OK so I found some copper washers and sorted exhaust for now. Cleaned out carb (which was filthy for brand new...) messed with the float a little and now fuel doesn't overflow. Still runs terrible on either CDI. Starts perfectly and sounds great for 2 seconds. Then dies hard. No choke/revs...

Like this? The old motor wasn't even running a copper gasket at all, I'll get one and hope that fixes the noise at least...is the YX150 a KLX style motor rather than CRF - would that mean I need a different exhaust entirely? I was hoping to keep the one on it for cost/noise factors. I'll do...

I just got back in after trying it, I went with my wiring as above using the YX150 CDI (did a rough job to test) - and gave it a kick. It started!!! Ran like absolute crap, but it started. The Madass exhaust didn't seem to bolt up right, and fuel was pouring out of the carb - so I'm not...

OK - back with more awesome MSPaint'ed photos haha - ignore wiring length I'll add length/joiners later - I'm just making sure I am on the right track for now! This wiring diagram seems identical to my current loom so far, so that's what I'm working off. It shows the ignition switch going to...

This is how it came. None of the loom colours match any other within itself and it has multiple 4 pin connectors...ugh. I was hoping to splice this into the existing loom as easily as possible...I don't mind chopping plugs off and soldering in joiners instead to make my life easier down the...

The bolt patterns between the arrows on #2 I have marked here? They are not the same, #2 is about 5mm wider. The flywheels are also much different sizes too. I feel like an idiot but there is no way the center nut is coming off on the old motor...I've tried all sorts of methods tonight and it...

You're correct, I kind of figured I wasn't going to be able to use the silver cover, it won't even come close to fitting the coil inside - all good. So you think I'm all good? Swap the flywheels over, bolt on the coil and away I go? Is there a trick to getting the center nut off? I put a large...

Hi again, so last questions hopefully! I've never pulled a flywheel off before so need a little guidance, I've done photos to make it easier. Flywheel puller should be in my hands tommorrow. Once again I appreciate how helpful you have been! Flywheel Remove nut marked with X, remove bolts...

Cool thanks, the motor actually came with an oil cooler I am just wondering whether it can be run without the cooler just at the initial stage. Sounds like it is a yes. Still waiting on that damn flywheel puller.

Still waiting! But I have another (probably stupid) question in the meantime. My motor came exactly like this. Is the pipe with the T-bolts (circled) an oil cooler bypass or just to block it? In other words can I run the bike like this or do I need to install the coil cooler to get oil into...

Sorry for lack of reply...still trying to get the correct flywheel puller. Bought the 26mm and it was too small (my tape measure skills suck), so now I'm waiting on a 28mm...fingers crossed I can get it before the weekend.

Ok so most of the parts have arrived and I got some time today! Was wondering if the master (my67xr) could give me some advice? The wiring hasn't been touched from stock madass, new motor bolted in but that's it. Old Motor as it sits now Old stator New motor bolted in New motor stator 100w...

Thanks yet again, I'll buy an electric start flywheel puller too (just in case) - so I'm ready to rock when all this stuff arrives.

Your link doesn't seem to work, but probably not. It's like this Pitbike Thumpstar DHZ Pitpro Atomik CRF50 Flywheel Stator Magneto Puller Tool | eBay