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Thanks for the kind replies.  Here it is on day two after some new gear oil, new motor oil, Prima magnetic plugs, new spark plug, a wipe down and a shot of Son of a Gun for that Richard Petty finishing touch.

I watched all three parts and liked it. It did not seem too big a ground-breaking a movie but it was informative in a one-sided sort of view. The usual throw it all together, sex it up a bit, and add some sentimentality TV movie. For me, who knew very little about these men, it was interesting.

I found some of the corporate intrigue interesting because of my background, but I agree there was probably too much of it. I would have liked a bit more time spent on explaining some of the mechanical ideas in their designs, It seemed like the show was made by people who retold what they heard about motorcycles.

I just received a new flywheel and installed it.  In doing so, I had an epiphany.  Not only was there the gasket in the wrong place, another source of the electrical problem was I had the wrong flywheel to begin with. 

My new GY6 B flywheel, in place, fits exactly as it should.  What's the difference between the two? 
GY6 flywheel: 110m in diameter.  GY6B flywheel: 111.9 mm in diameter.  I was, all this time ~.95mm further from the magneto than I was supposed to be.

This also poses the question; "how the %@*& did I get a scooter with a GY6 flywheel that had the center section of a GY6B (wider taper)?" 

Looking very good so far.

I started out very slowly on the scoot with the new CVT setup. I resisted the temptation to go fast for about half a tank. I returned some of the tools I had borrowed and slowly went faster and faster. Going on a straight shot North, I eventually eased it to about 60 mph, seemed fine and was not even taxing it too hard. I did noticed how the gear ratio seems to stay lower from a stop because the engine growls a bit, in a very satisfying way.

Unfortunately for me, as I was heading to return the hole saw to the friend who suggested the vent, the throttle cable snapped at the tube while I was executing a slow speed right turn. Luckily for me, the same buddy gave me a lift home. The last couple days have been spent doing small repairs while I reroute the new throttle cable.

I'll post again when I'm back on the road.

My friends suggested I vent the case and even offered to let me borrow a 3 1/2 inch hole saw.  I did so and it came out pretty well.



And here is a video me starting it the first time after buttoning it up.



Noticing the wheel move pretty fast at start up I have backed out the idle screw a good turn.  I have since been riding it around, a bit slowly, to let it break in. I cannot give a full report yet but "so far, so good."

After cleaning everything and reassembling I would say it was a bit tricky but not too hard to do.  The NCY kit comes with "rollers" or the tiniest ball bearings you have ever seen.  Exhale near them and they go flying.

I had some struggles getting my two part pins back in the Primary, but the new Secondary fit snugly.  Then the challenge of getting the little balls smaller than the head of a pin to fit neatly into the two part spring seat.  I had an easier time than expected pressing the new clutch and spring down on the post and not losing the little bearings.  Using the well documented two hands down, then replace with your feet method, I secured the 42(!)mm clutch nut.  I then used my vise grips in the open and extended position like it was a spanner wrench to put the nut back in place.  A sigh of relief.

The Kevlar belt was very stiff but I massaged it into position.  This is the only time nearing 100 degrees outside worked to my benefit.

Here's a picture.