Unreal Pinto

Working on my cousin's kick start E50 for his Sprinter Pinto.

My first time working on a kick start version of a E50:

The tear down

Pulled the clutch

Just Another Polini E50:

Installing the run of the mill Polini Kit on this build. Therefore, pressed in some aluminum "stud spacers" for better case matching.

Done!

Let the porting process begin:

Familiar gasket mark-ups

Let the metal fly!!

Case split

Basic match porting. Nothing too crazy.  Not aiming for top end since its mainly gonna be used as a sprinter.  Kept the transfers fairly shallow.

Just enough to match

Don't forget the boost ports

Finish product

Ready for the crank

Just another Dio Polini:

My cousin had a chance to ride my first E50 Dio Polini build and was impressed. Naturally he wanted to go the same route. I again used a Motomatic adaptor. I match ported the adaptor to the manifold and the cylinder like I did before. The only difference this time I decided not to fill the void with JB weld. I wanna see if it makes a difference.

Honda Power

Motomatic adaptor

Match and cut

Fuel path

Did the typical work to the cylinder (chamfering, cleaning, polishing, etc). Ported out the intake a bit. Nothing too drastic.

More fuel

I went with the low compression 50cc head for this one:

Down the barrel

All port work done and ready for reassembly:

It's a go

Mock up

A personal commentary:
From my experiences with Polini kits on both E50s and ZA50s, I feel that there is little that you can do to screw up or impove this kit. Whether you port and polish it or not, case match it or not, run large carbs or not, aftermarket pipe or not, this kit just out of the box will automatically kick a$$. The only think you have to manage is not blowing it up. I think a lot of people take a little too much credit on what they said they did to this kit that made their polinis "fast" where majority of the credit should be on the polini kit itself. I remember a guy on his blog claiming to have the fastest Puch cause he had all these so called secrets he did to his E50 and Polini kit. He clocked in at 55 mph I think. YOU COULD HIT 55 WITH A POLINI OUT OF THE BOX!!  RIDICULOUS!! Unless you drastically change the port timing, compression, etc, and breaking 60 mph to 70 mph, then you deserve credit. Other than that, we should all thank Polini for putting out a kick ass kit for our Puchs to enjoy.

Happy Tuning!!