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Yea 80 is too small and probably the main reason your top end burned up. Start with an 88 or 85 and go from there, and keep the stock airbox for sure.
Yes the Zumas are geared differently than the China cases. You will want to look at getting 15/50 or 14/fortysomething upgears for your Zuma because the '02-'05 models had taller gears and therefore lower top speeds.
Also if it fits use the clutch and rear pulley from your China scoot, the '02-'05 Zumas have a terrible clutch (2-shoe that breaks easily) and rear pulley (sliding sheave with weird curved tracks that mess up your acceleration/shifting.)
And replace the Zuma's metal reeds with Carbon ones so they don't destroy your engine when they break.
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2005 Yamaha BWS (Zuma) "Garfield"
TP Black Trophy 70cc, Giannelli Reverse Pipe, 5g Dr. Pulley Sliders, Delta Clutch with Yellow Springs and Yellow Contra, Malossi Torque Controller, Naraku R-Vent Bell, NCY Adjustable Secondary Sliding Sheave, CF Reeds, Kege Analog Tach, Dual Headlight Mod, N.A. Rear Fender Delete, OEM Short Windshield.
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