HONDA RUCKUS Z125 SWAP

WE WILL  BE BUILDING THIS

RUCKUS Z125 SWAP

 

FROM  OUR 2009 ZUMA 125

ZUMA 125

 

HONDA RUCKUS

This all started about five years ago when I traded a Jeep on a 2003 Honda Ruckus.  I did the normal mods and within a few months and then  I was searching for one for my wife Karen.  We then purchased a super clean Sno Camo Honda Ruckus and we were hooked.  We enjoyed the bikes but for all practical purposes for where we live they just didn’t have enough power, even doing the mods to get them faster.  I then located a 2009 Yamaha Zuma 125 and believed we found the perfect match.  We then purchased another Zuma 125 for my wife and did the normal mods like lowered, headlight conversion, bigbore etc.  I ended up selling off the there Ruckus we had in the corral and missed them ever since. We really enjoyed the Z125’s but we really liked and loved the way the Honda Ruckus were.  So this begins the swap to part out her Yamaha z125 and build her the Ruckus they way it should have been all along.

2003 Honda Ruckus

This is our first 2003 Honda Ruckus.

 

 

 

 

 

 

 

 

Sno Camo Ruckus

 

 

 

Karen’s 2007 Sno Camo Honda Ruckus

 

 

Red and Camo

 

 

 

 

 

 

 

 

Karen and I riding in California

 

 

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Later model silver      Sno camo

WE FOUND OUR LOW MILEAGE RUCKUS

We searched for a bit and came up with a 2011 Honda Ruckus with very low mileage.

Honda Ruckus low mileageIMG_3485_zpsjuemipc7IMG_3484_zpsncjjrpox

TIME TO TAKE RUCKUS APART

We separated all the parts so we can eBay all the part we don’t need and reclaim some of the money.

 

RUCKUS 125 SWAPIMG_3489_zpsn8xepef1HONDA RUCKUS Z125 SWAPIMG_3485_zpsjuemipc7RUCKUS Z125 SWAPIMG_3514_zpsliorwdnz

 

2009 YAMAHA ZUMA 125 DONOR

Was kind of a shame to part out a perfectly running 22o0 Mile Yamaha Zuma but its the only was to have everything you need to do the swap. Its the second one it the picture.  The one in front will be the next one I do.

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YAMAHA Z125 TAKEDOWN

 

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After looking over all the parts its was time to start mocking up.  I ended up taking the lower triple clamp off the Zuma 125 and I cut the stem off it and drilled it out to fit the Ruckus stem.  It was kind of a bitch to do but then I was able to use the Zuma fork and brakes.

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I then used a piece of thin plastic and drew out how I wanted the lower brackets to look like.  I was tempted to order a set online but I wanted to make them my self.  After I took to a friends shop and he water jetted me a set out of 3/16 plate.

Ruckus lower engine bracket

 

 

Next I cut out the bottom of the Zuma 125 tank to fit into the Ruckus tank. And here is the Ruckus tank that I cut open to make it all fit.

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Here is the piece I cut out of the Zuma 125 tank to fit the Ruckus tank.  Not a great fit but I can make it work.

 

 

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I ended up sand blasting the Zuma tank piece and started to weld it into place.  This is what I ended up with.  After I took it to a radiator repair shop and had them line it so it wouldn’t leak.

 

 

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We did a little mocking up and made the lower engine mount.  Sorry I can’t find the pictures but when I pull the bracket off again I will snap some pics.  I also used a thomson bar stem with some carbon fiber bars I bought on Ebay.  Out of all the Ruckus’s I have bought I have never purchased a lower seat frame, I just cut the tube shorter and smashed the tube back down in the vise, drilled holes and bang lower seat frame.

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Heres a few pictures I had taken during to process. I ended up using the factory Ruckus tail light in which I cut the bracket down to lower the light by about 4 inches.  I also ended up using the Oem Zuma blinkers with the clear lens.   If you look at the third picture in this series you will notice I used a Snapon shorty wrench and a kick stand.  I still need to order a side stand for this bike.  I also like the picture of the Ruckus next to my other Zuma 125.

IMG_4210_zpspt4996gw RUCKUS Z125 SWAP IMG_4233_zps61nw75ls IMG_4234_zpscavxutdq IMG_4236_zpsatt6xw8d IMG_4238_zpsk7yopcho RUCKUS Z125 SWAPIMG_4246_zpsz7larhs4

 

Time to get this thing wired and running.

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I bought a harbor freight electric winch a few years back and it comes in handy when needed to lift the bike up to working height.  At this point I was moving the wires around to make everything fit.  I ended up pulling the wiring case off and moved the fuel pump, tip solenoid, fuse box and extended the battery cable to reach where the factory Ruckus battery sit.

RUCKUS Z125 WIRING

 

Another view and a picture of my street legal CRF50.  This 50 has a 106cc stroked 5 speed in it. This little bike is super fast.

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Here is about how it sits with me on it.

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This is the Ruckus my wife loved and we sold.

 

 

Sno camo

And this is the new and improved.  I think she will like it.  But I think I will look for some camo parts.

RUCKUS Z125 SWAPPED

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TOYOTA SEQUOIA SWING OUT TIRE CARRIER

TOYOTA SEQUOIA SWING OUT TIRE CARRIER

SWING OUT TIRE CARRIER TOYOTA SEQUOIA. I DECIDED TO BUILD A TIRE CARRIER THAT WOULD WORK WITH MY EXISTING FACTORY BUMPER. NOT A NORMAL EASY THING TO DO BECAUSE THERE IS NO FRAME THERE TO SUPPORT THE SPINDLE FOR THE HINDGE SO THE FABING BEGINS.

SPARE TIRE 

HINGE SUPPORT

DRILLED SOME ONE INCH PILOT HOLES THEN USED A HOLE SAW TO GET CLOSE TO THE SIZE IS NEEDED TO INSTALL SPINDLE PILOT HOLES FOR SPINDLE

STILL WOULDN’T FIT SO I USED THE DIE GRINDER TO FINISH OFF THE HOLE AND IT POPPED RIGHT IN.

 

 

SPINDLE HOLE CUT AND DIE GRIND

PURCHASED THE A-Z FABRICATION HEAVY DUTY SPINDLE FOR THIS APPLICATION   SPINDLE TRIAL FIT

I ENDED UP CUTTING SOME THE BOTTOM AWAY CAUSE IT WAS HITTING THE INSIDE OF THE BUMPER AND I FIGURED IT WOULD GIVE ME A LOWER SPOT TO WELD TOGETHER.

SPINDLE ASSEMBLE

 

CUT A PIECE FOR THE LOWER PART OF THE TIRE CARRIER AND I NOTCHED THE END SO IT WOULD FIT BETTER.

 

 

TIRE CARRIER SUPPORT BEAM

NOTCHED THE BUMPER AND INSTALLED IT TO SEE HOW IT WOULD LOOK TRIAL FIT.

CUT OUT BUMPER AND CHECKED FIT

 

CUT A SUPPORT BRACE FOR THE WHEEL AND TIRE.  I WASNT SURE HOW TALL TO MAKE IT SO I LEFT IT TO STICK OUT ON THE TOP TELL I DECIDE IF I WANT TO MOUNT ANYTHING ELSE ON TOP OF THE SWING OUT TIRE CARRIER.

 

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SO FAR I THINK ITS LOOKING GOOD AND ITS ALL MOCKED UP BUT I HAVE NOT FINISHED THE WELDING YET IN CASE I WANT TO MAKE A FEW CHANGES.  I ORDERD A SCEPTER FUEL AND WATER CAN BUT THEY HAVE NOT ARIVED YET.

 

 

 

IMG_1128LICENSE PLATE MOUNTED 

IM STILL WORKING ON THE LATCH AND CATCH .  BUT I DID GO AHEAD AND MAKE A LICENSE PLATE HOLDER.  I DROVE THE TRUCK AROUND FOR A FEW DAYS WHEN I NOTICED YOU COULDN’T SEE THE PLATE MOUNTED UNDER THE TIRE.

 

Toyota sequoia

Toyota sequoia

SCEPTER FUEL AND WATER CONTAINERS AND HI LIFT JACK.

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HERE ARE A FEW PICS MY WIFE TOOK WHEN WE WENT TO COW MOUNTAIN TO TRY THE SEQUOIA OUT.

 

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I WOULDNT HAVE THOUGHT THE SPARE TIRE AND CAN MOUNT COULD DRAG ON THE GROUND.  I GAVE IT LIKE 3 FT CLEARANCE.

 

 

TOYOTA SEQUOIA UNWANTED WOOD TRIM

 

2002 TOYOTA SEQUOIA WOOD TRIM REMOVAL

TOYOTA SEQUOIA UNWANTED WOOD TRIM REMOVAL.  I FIRST PRICED THE NEW PARTS FROM TOYOTA AND FOUND IT TO NOT BE COST EFFICIENT I COULDN’T BELIEVE HOW EASY IT WAS TO REMOVE.  I WAS GOING TO PULL ALL THE PARTS AND PAINT THEM, TELL I FOUND OUT IT WAS REMOVABLE. THIS CONSISTED OF WAY LESS WORK WITHA BEAUTIFUL OUTCOME.  HERE IS A SHORT VIDEO

IT CAME OUT SUPER CLEAN CHECK OUT THE FINISHED PRODUCT.  IT LOOKS LIKE HAMMERED STEEL

TOYOTA SEQUOIA UNWANTED WOOD TRIM

AFTER I DID THE DOORS I THOUGHT THERE IS NO WAY THE RADIO SURROUND IS THE SAME WAY.  LOW AND BEHOLD IT REMOVED IN THE SAME WAY.

OUT OF ALL THE PIECES IN THE TRUCK THE RADIO AND CENTER CONSOLE WERE THE TWO I DISLIKED THE MOST.  AFTER REMOVING THEM I WAS PLEASANTLY SURPRISED HOW MUCH MORE I LIKED THE INTERIOR.  SUPER SUBTLE  AND A WAY BETTER LOOK.

TOYOTA SEQUOIA UNWANTED WOOD TRIM

2002 TOYOTA SEQUOIA LIMITED 3 INCH BODY LIFT

                                                                                                 Toyota Sequoia 3in Body Lift

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AFTER SEARCHING THE INTERNET TO THE NEAR VERY END I DECIDED TO LIFT MY 2002 TOYOTA SEQUOIA LIMITED. I WANTED TO INSTALL THE BILSTEIN 5100 BUT THEY ARE ON BACK ORDER SO I USED THE PROCOMP STRUT SPACER AND OME EMU REAR SPRING FOR A 3 IN LIFT ALL THE WAY AROUND. I STILL WANTED TO GO HIGHER SO I DECIDED TO MAKE MY OWN 3 INCH BODY LIFT. I WILL BE PUTTING TOGETHER SOME BODY LIFT KITS IN THE NEXT MONTH IF ANYONE IS INTERESTED. A LOT OF PEOPLE SAY THESE ARE GROCERY GETTERS OR MALL RIGS. IM GOING TO TRY TO MAKE THIS A NICE RIG. I WANTED TO BUILD A VEHICLE THAT ARE NOT MODIFIED A LOT.  I DONT WANT IT TO LOOK LIKE A SOCCER MOM TRUCK. SHOOT ME A EMAIL IF YOU LIKE.

HOOD MOUNTAIN SANTA ROSA, CA

3IN BODY LIFT TOYOTA SEQUOIA

TOYOTA SEQUOIA 3IN BODY LIFT

Body lift, hood mountain

SOME PICTURES WE TOOK UP AT HOOD MOUNTAIN SANTA ROSA CA.  NEW LIGHT BAR INSTALLED AND IF YOU LOOK CLOSE YOU CAN SEE OUR DOG LOOKING OUT THE FRONT WINDOW.

 

 

Way Motor Works Stratmosphere Exhaust

Purchased the Way Motor Works Stratmosphere exhaust.

Installed

Stratmophere Exhaust

WAY MOTOR WORKS STRATMOPHERE EXHAUST. All I can say is wow when I opened the box I couldn’t believe how nice of a job they did on the welds. Truely a fine piece of work. This exhaust looks and sounds amazing.

Super clean exhaust

 

DID A QUICK LAYOUT ON THE GROUND.  THIS UNIT WEIGHS NOTHING AND WAS AN EASY INSTALL

Nice welds

 

If you have an 02-06 R53 MINI Cooper S this is the catback exhaust you want. The stratmosphere is the most beautiful exhaust on the market in every way. The look, the sound, the fitment, the craftsmanship. You get dialed-in fitment with hand-finished components by the builder topped off by double-chrome stainless WMW tips. This system is extremely easy to fit very quickly and behaves with a sound that everyone will enjoy. Systems are fully stainless inside and out and have been tested and verified at our USA headquarters. This is a full catback exhaust system. It bolts directly to the flange behind the factory cat so no cutting or welding is required and your emissions is NOT effected. The stratmosphere catback is made entirely of stainless steel so it will most likely outlast the car. This MINI Cooper S catback exhaust will improve the exhaust flow while balancing the back pressure to give you maximum torque gains. But at the same time this exhaust will give you a nice tone, a little louder than stock, and no ricey honda sound. Also is has NO DRONE on the highway, a big plus as this is a common problem with most other exhausts. Way Motor Works uses this exhaust on his person car, and 2 other family members MINI’s, so that says alot.

Built to the same specs as the Milltek, just a cheaper price

Mini Cooper S Clutch

2004 mini cooper s clutch.  I decided to replace my clutch in which was slipping. After talking to many people about what clutch to install ( single mass flywheel) or factory (dual mass flywheel).  I talked to Way at Way Motor Works and he said the best bang for the buck and driveability is the Valeo single mass flywheel and clutch priced at $ 450 for everything.  And besides the clutch we replace the rear main seal, throwout bearing guide, throwout bearing arm bushings, cv boots, water pump, supercharger oil, oil pan gasket, crank angle sensor seal, lower control arm bushings, radiator and front main seal.  I have to say after I finished the job which did take a while I’m amazed at the improvement this service has made.

 

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