Scooter tuning, how to properly tune a scooter

Scooter tuning, how to properly tune a scooter Scooter tuning using the example of Honda Dio AF-18 Remove 50 - put 72. Replacing the piston on a scooter CVT tuning. Adjusting the weight of the variator weights using available materials

How do you do your own scooter tuning? Why does a scooter need tuning at all? To answer, we need to figure out why we need a scooter at all?

It’s one thing when a scooter makes it possible to forget about traffic jams and heat, and the fuel consumption is minimal. Everything is clear here with fifty dollars - the time comes when more dynamics and maximum speed are required/wanted. By intelligently approaching increasing the performance of a scooter, we will get the desired result. It’s another matter if we have a scooter as a means to stand out from the crowd, to amaze everyone with amazing acceleration and an impressive bass note from the exhaust. Here the direction of tuning is completely different. And in general, it often makes sense to simply change the scooter to a more powerful one rather than tuning a fifty-kopeck piece.

Speaking of low-budget boosting, click here, Cheap tuning of the Honda Dio scooter, and read the article about wallet-friendly tuning.

Well, later in this article we’ll talk about how and what to do for tuning, and for serious tuning of a scooter, with your own hands or someone else’s, and most importantly, wisely. And to such things as His Majesty, sir, “big scooter tuning”, i.e. Scooter tuning, which is noticeably superior to budget ones both in scale and in cost, must be approached extremely meticulously and carefully. This means that you can’t do it without the skill and instinct of a mechanic.

However, let’s start small here too.

So, after running in and removing the speed limiters (chokers), we have several ways to increase the maximum speed a little and get a much more powerful engine with almost the same resource. Don’t forget about the technical condition of the remaining parts and components of your scooter, otherwise the simplest and most inexpensive do-it-yourself tuning can result in a rather complicated and expensive scooter repair! already, perhaps, by someone else’s, more skillful hands . So:

Change the scooter muffler to a tuning resonance pipe that fits your CPG (pipes such as Laser X, LeoVince ZX, Technigas Next - R in various versions may be suitable) or to a “torque” exhaust (Polini No Smoke, LeoVince SP3/Turing, Techigas Silent Pro). Also rebuild the transmission part in accordance with the characteristics of the installed tuning pipe. This will allow you to raise the maximum speed of the scooter by another 10-15 km/h (for resonant exhaust) and will give an increase in dynamics.
Get a carburetor with an optimal diffuser diameter. For 50-70cc, the most convenient to configure and install is a carburetor with a diffuser diameter of 17.5 mm, the most commonly used carburetor. There is an opinion that DellOrto tuning carburetors are of the highest quality, although by and large, the manufacturer does not really matter.
CVT - replace with a sports one. In tuning CVTs, the process of adjusting to new parameters of a scooter’s engine is more accurate and of better quality - due to more advanced kinematics of moving weights. Tuning CVTs produced by Polini after 2005 are equipped with a rod lubrication system, which increases the efficiency of the entire scooter transmission. And due to the smoother and easier movement of the variator cheek along the guide sleeve, it improves the acceleration response of the scooter.
The main way to increase the power of a scooter is, of course, to install a Sport class of increased volume. Generally speaking, this is the most radical and most effective method of increasing the performance of a scooter. Thus, you not only have an increased cylinder volume, but also a more competent and thoughtful system of the cylinder purging process (for a two-stroke engine) - that is, even more power. The main difference between two-stroke piston tuning kits from different manufacturers is precisely the different placement of windows. A cylinder head with an optimized combustion chamber shape - usually complete with a tuning CPG. Keep in mind that when installing piston engines with a larger piston diameter (volume), it is extremely important and necessary that the crankshaft and bearings be in perfect technical condition, otherwise large loads will simply destroy them very quickly.

In principle, the average person can stop at this level of scooter tuning, because the next stage is do-it-yourself scooter tuning, which allows you to develop up to 12-17 hp. on the shaft - this is the “design” of an engine on a tuning piston class Mid-Race and Race. And this is a qualitatively new level of tuning, and as mentioned above, for many it is easier to simply purchase a more powerful stock scooter than to tune it. So, tuning Mid-Race and Race class scooters.

Such engine tuning requires the installation of a reinforced crankshaft - with suitable bearings and a corresponding reinforced connecting rod. Only such tuning parts of a scooter engine are able to withstand increased shock loads and realize new power. Otherwise, you can forget about stable and trouble-free operation of the engine.

The crankshaft speed of an engine of this class begins to set the rhythm. 10,000 rpm requires adequate reliability of the components, which stock (i.e. standard factory) parts, such as main bearings, are not able to provide. In addition, the new thirsty engine needs appropriate power - the diameter of the carburetor diffuser should not be less than 17.5 mm for a racing piston engine. Also, the carburetor setting for this tuning engine must provide a good mixture at high speeds, otherwise overheating and further “sticking”, and in severe cases, the wedge of the cylinder cannot be avoided. It would be nice to install a 19 mm carburetor paired with a tuning sports air filter.

In fact, all the following steps for further tuning the scooter with your own hands will repeat the previous stage of boosting, only with the difference that it is necessary to use higher quality and more productive components of tuning kits. That is, instead of a regular sports CVT, it is strongly recommended to use Polini Evo or Malossi OverRange transmission tuning kits.

Tuning in this class allows you to develop dizzying dynamics and a hurricane maximum speed of over 100 km/h. In general, for normal use of a scooter in the city without too much investment in fuel and lubricants and consumables, this is the maximum possible tuning of the scooter. But such tuning allows you to enjoy real amazing dynamics and speed (this especially traumatizes the already unstable psyche of drivers of pseudo-sports cars, who for some reason underestimate the possibilities of tuning a scooter with their own hands and are perplexed when a “crazy stool” gives them heat from a traffic light as if they were standing , and often leaves them no chance for revenge ).

So we have reached the pinnacle of boosting - tuning a Hi-End . These are uncompromising solutions that allow you to increase the liter power of a scooter engine to a figure exceeding 300 (three hundred!) horsepower per liter of volume! And this is without the use of all sorts of turbines and other sophisticated solutions like nitrous oxide or special fuel!

There are not so many companies involved in such developments. The main players in this field are Malossi, Polini, Kunda, 2Fast, Fabrizi, MetraKit. These are elite components and a triumph of high technology.

With this tuning, engine speed comes close to 20,000 rpm! There can be no savings here, the work is only for the result - the task of such a motor is to work out two 15-minute sessions and several hours of training, after which it is sent for inspection and subsequent replacement of worn-out components. Even crankshaft bearings most often come in special series and can only be purchased from the tuning studios themselves (Malossi and Polini have their own special bearings that were developed and manufactured exclusively for them).

Installation of the crankshaft, CPG and other components requires a very serious modification of the engine crankcase and chassis of the scooter; the use of rotary ignition is mandatory (which allows you to spin the engine to insane speeds without losing spark power), which implies the absence of all electrics not related to the scooter’s ignition system . The ratio in the gearbox is left to the taste and wishes of the owner.

The best examples of fine-tuning scooters using components of this class allow achieving time at a completely “adult” distance of 402 meters within 12-14 seconds, and not everyone, even seriously “charged” cars, are capable of such “feats”.

In urban use, the service life before replacing the ring is expressed as a figure from 1500 to 4000 km, so if it is possible to “feed” such an engine with first-class 98 gasoline (not the kind that is poured at 99% of gas stations, but real) and very expensive oil, then you can and sometimes ride such a monster to scooter-moto parties and amaze the imagination of those passing by with shining sides and polished engine covers, and after the cool motorcycle racers stop nervously giggling from the chirping of a newly started engine, accompanied by a fair amount of smoke from the exhaust pipe (you will have to pour oil “by eye” and, preferably, and, naturally, in not the most optimal proportions), open the trigger fully and take out a couple of “purebred” (ZZR 400 =) sports bikes. So let someone after this say that scooters are consumption for children “under 16”...

This, in general terms, is all about tuning scooters with your own hands. But each scooter is unique, each scooterist has his own requirements, so each scooter should be prepared based on many conditions - budget, requirements and the feasibility of one or another modification, because it is not for nothing that there are so many “transitional” classes on the scooter tuning market that do not fit into the standard ones the framework of one or another forcing class.

The following is a list of tuning kits provided by various scooter parts manufacturers.

Scooter tuning - CPG tuning

The variety of tuning cylinders offered is quite large, including standard 50cc and more powerful 70cc. Standard 50 cc tuning cylinders provide an increase in scooter power due to the improved design of the cylinder itself, and 70 cc cylinders also due to a 40% increase in volume. In this case, the scooter becomes much faster than stock.

But comparing cylinders of the same displacement, it is clear that they all produce different results. This is due to the fact that different cylinders are designed for different operating speed ranges of the engine. Hence the differing effective power. Tuning cylinders for scooters are usually classified into Sport, Midrace (Racing) and Hi-End. The lifespan of the scooter's Sport cylinders is approximately equal to the lifespan of the standard ones, since these cylinders are adapted to the same engine speed.

In addition, these Sport class cylinders are usually no more expensive than similar standard parts

Different racing tuning piston class Racing 70cc differ from each other. These are such manufacturers of CPGs as Top Due Plus, Polini Corsa, Malossi MHR Replica, Hebo Manston Replica. For example, cylinders from Hebo and Malossi have high quality, wear resistance and power. These are aluminum CPGs with a very durable chrome-nickasil coating. Cast iron racing scooter cylinders from Top Performances and Polini are generally just as good. An aluminum cylinder undoubtedly has the best heat transfer. But if it is damaged, you will have to change both the piston with rings and the cylinder (this can happen from, for example, a lack of oil in the mixture, or when it is depleted). However, cast iron piston engines in such emergency situations can only get by by replacing the piston, and the surface of the cylinder should be polished. Racing cylinders have much higher compression and compression ratios (up to 14:1), as well as engine speed. All this requires mandatory strengthening of the crankshaft; it should be replaced with a tuned one from a racing kit.

Cylinder-piston group.

Finally, the most effective improvement for any engine is replacing the CPG. But not just a replacement, but the installation of a new, larger piston. Fortunately, there are now many ready-made kits on the market; you don’t have to sharpen or adjust anything, as with Soviet equipment. Moreover, there is even a lot to choose from. For example, for various models with a volume of 50 cubic meters, they offer kits to increase to 63, 72, 82 and even 90+ cubic cm. In some cases, this is an almost double increase in power.

The situation is similar with larger engines, for example, for 125 cubic meters, sets of 150 or 170 cubic meters are sold. Some, in the process of tuning a scooter, manage to increase 150 cubic meters with their own hands to 225 cubic meters. Choosing the right part is not the most difficult thing, the most difficult thing is installing it. After all, this process involves almost complete disassembly of the engine. You will be faced with the need to have several special removable keys in your arsenal; you can ask them from friends or borrow them for the evening at auto repair shops. We strongly recommend studying the technical component in order to properly disassemble, replace the necessary elements and assemble the motor.

Alas, for some, increased power does not promise anything other than breakdowns or inadequate performance. This is because by significantly increasing power, you inevitably entail work on all other nodes. Let's imagine that we installed a new 92 cc CPG on an old 50 cc engine. The first thing to check is the condition of the connecting rod, crankshaft and bearings. Otherwise, they will fly first, followed by our new system of both cylinder and piston.

Great, we added new bearings to the CPG, an elbow with a connecting rod, now we can be sure of reliability. But the engine does not go faster, and we decide to purchase a new carburetor. Now the mixture is too rich, and we understand that the exhaust needs to be changed. After such modifications, the engine sounds loud, accelerates perfectly, but the maximum speed is slightly higher than before and the variator sounds strange. After installing a high-speed CVT, for example from the Italian manufacturer Polini, the engine will be able to fully realize its new power. The last stage is an inspection of the brake system; you don’t want to find out at a speed of 60 km/h that the brakes are now comparable to bicycle ones.

As a result, after replacing almost all the components, we got a very fast “flea” that can surprise your friends and experts in this technology. Over time, you can make changes to the chassis system, replace shock absorbers, and install more attractive wheels. Often, the modernization process does not stop there, and after tuning a scooter 50, 150 with your own hands, impressive improvements in appearance are made. The moped is repainted, panels are changed, new devices, lighting, and so on appear.

Scooter tuning - crankshaft tuning

Once you have decided on the cylinder, the next question is whether to change the crankshaft. The answer to this largely depends on the class of cylinder that you have chosen for yourself. When using Midrace and Hi-End class cylinders, replacing the crankshaft is mandatory! Installing cylinders of the indicated classes in combination with a standard crankshaft is a gross violation and an indicator of the unprofessionalism of the people involved in installing parts on the scooter.

In all the variety of tuning crankshafts, it is necessary to distinguish two groups. The first one is simply reinforced

. They replicate the corresponding standard crankshafts in all respects, but have greater strength (and therefore a longer service life), as well as improved heat removal from the piston pin. Reinforced crankshafts are great for use with Sport class piston when there is a need to replace the standard one.

The second group is racing crankshafts (the abbreviation HPC is often used - high primary compression). Such crankshafts significantly affect engine performance, as they provide an increase in the compression ratio in the engine crankcase. This significantly improves the efficiency of cylinder scavenging at high speeds, providing an increase in power. At the “lower” ranges, the efficiency of purging, on the contrary, suffers, but for forced engines this is not significant. Racing crankshafts are indispensable when it comes to tuning based on Racing class piston engines.

When replacing the crankshaft, it is recommended to replace the main bearings with oil seals.

Scooter tuning - muffler tuning (exhaust system)

A good exhaust system can easily help you add horsepower to your scooter. The operating features of a two-stroke engine are such that a well-chosen exhaust system can increase power by up to 20%, which is a very significant amount. Moreover, modern scooters, forced to meet the most stringent environmental requirements, are equipped as standard with exhaust systems that have a detrimental effect on performance.

Exhaust systems, like cylinders, are divided into different classes, so you need to choose a system based on the piston system that will be used on the scooter. Sport class exhaust systems are quite versatile. Many of them show excellent results with both standard 50cc cylinders and 70cc Sport class cylinders. But not all, so you should be careful when choosing. Pipes from certain manufacturers have proven themselves to be extremely short-lived and fragile, so you should not buy the first pipe you come across.

Chrome-plated exhaust systems deserve special attention: they retain their appearance much better and are also protected from corrosion, which is very important in Russian operating conditions!

Manufacturing of individual snowmobile elements

The principle of converting a motorcycle, chainsaw and moped is almost the same. If you learn how to make individual elements, it will be much easier.

Suspension

When converting a vehicle into a snowmobile, special attention is paid to the rear suspension. It definitely needs improvement. To make it you need to prepare:

After preparation, you can begin making the pendant:

The front arm is connected to the sliding rails on one side and to the chassis on the other using hinges.
Do the same with the rear lever.
Position the torsion springs between the sliding rails and the rear torque rod.
Place the fastening of two power elements between the suspension arms.

To secure the suspension, use tie rods.

Engine

Choosing an engine for a snowmobile is an important step, since the power of the vehicle and its ability to move on snowy roads depend on it.

The optimal engine power for a snowmobile is considered to be in the range of 6-30 hp. With.

Therefore, most often these vehicles are made with a Lifan engine or with a part from a motorcycle or moped.

Snowmobile lift

This device may be needed if your snowmobile is stuck in the snow or needs repairs. It’s not difficult to make a kind of jack:

Make a channel-type structure from a metal corner 25 mm wide. Height - 19 cm. Make two holes in the middle for attaching the fork.
Weld a plate to the bottom that will act as a guide. Place a similar part on top, but do not fix it. The distance between them is 14 cm.
Make holes in these plates through which to pass the jack pipe. Make the top one spring-loaded.
Next to the top plate, place another part at an angle, which will act as a hook and hold the spring-loaded part.
Make a fork for the lift. Its length is 12 cm. Fix one side in the channel. Place the second fastening axis at a distance of 67 mm. Insert a piece of pipe into the fork that passes through the second axle. Weld a metal ring to this pipe (you can take a metal plate in which to make additional holes for rubber bands), through which you pass the jack pipe.
Secure this ring with motorcycle rubber bands to the area under the spring of the top plate. To prevent the elastic bands from slipping, they can be secured with screws.

Wheels

For good cross-country ability, the vehicle is built on inner tubes. Snowmobile wheels must be large in diameter. But it is better to equip the structure with skis. They can be made from plywood and large diameter pipes. If there is such an opportunity, then they can be taken from another snowmobile, including a children’s one. Additionally, it will be necessary to make rotation bushings for them, while the presence of bearings in this system is not necessary.

Homemade tracked snowmobiles perform well. It is possible to make this part yourself. The caterpillar is driven by wheels that are located inside it, for which wheels from garden equipment are suitable. The part itself can be made of plastic pipes, even if two-track snow scooters are made. Pipes with a diameter of 4 cm are suitable. If they are cut, they can serve as caterpillar lugs.

Regardless of what vehicle is being converted to a snowmobile, how extensive the modification is, or who built the design, it is recommended that it be tested in an open area first. If they passed without problems, then you can go to longer distances.

Scooter tuning - carburetor tuning

You can get more complete output from a larger-volume piston by appropriately improving the operation of the power system. First of all, we are talking about the carburetor. Scooters come standard with carburetors from a variety of manufacturers, but they all have a common feature by which they can be classified - the size of the diffuser.

On standard 50cc engines there are carburetors with diffusers from 12 to 17.5mm. Tuning carburetors are also diverse: there are cases of installing even 28mm carburetors on 70cc tuning engines, but all this is already in the realm of experimentation. Carburetors with a diffuser diameter of more than 17.5 mm (19, 21, 24, etc.) are impractical to operate and require regular attention and reconfiguration. Of course, all this is not important if you are going to make a street rocket out of a scooter, sacrificing convenience and reliability.

A standard and proven recommendation for 70cc cylinders is to install a 17.5 carburetor, if one is not included in the standard equipment (for example, on the latest Piaggio HiPer2 engines).

Scooter tuning - air filter tuning

To properly power the engine, you need not only gasoline, but also air. Excess gasoline will do nothing for your engine unless it is enriched with enough air. To improve the air supply to the cylinder, special air filters are used. The most universal and balanced solution is to use a more efficient filter element, for example, Malossi Red Sponge, instead of a standard filter element. It is installed in the standard air filter box.

Another type of tuning air filters is the so-called zero-resistance filters (or simply - FNS). When installing them, the standard box is completely removed, and in its place is a small filter element, usually either cylindrical or cone-shaped. It has less resistance, which improves cylinder power at high speeds. However, firstly, these filters are almost not protected from external influences of dust, dirt and water, and secondly, unlike standard air boxes, they do not have a resonance effect. As a result, installing such a filter requires a thorough and precise reconfiguration of the carburetor, which only a few specialists can handle. If the service center tells you that they can “simplely” and “easily” set up a carburetor to work with the Federal Tax Service, most likely the qualifications of the workers there are below average. Leave and never come back!

Where to start assembling a motorcycle with your own hands?

You can also create wheel rims with your own hands. Still, why “reinvent the wheel” if many compatriots know from practice how to make a motorcycle from the Urals or Dnieper MT, using the frame, engine and electronics of the latter. By adding other unique nodes to them, you will clearly get an iron horse that is unlike any other.

Having installed an extended fork (preferably adapted for a front disc brake), homemade traverses (created using a steel sheet with a thickness of several tens of millimeters), the bike’s handlebars are mounted using brackets. The brackets are also used to mount the rear shock absorbers. They are considered a secure base for holding the seat back. Here you can fix various panniers and the trunk of the bike.

How to assemble a complete homemade motorcycle

Also make sure that in the future your homemade bike can be placed on a leg as easily as possible when parked. For these purposes, it is better to choose a side knife, which is mounted on the left side member of the frame and has the ability to easily recline in the presence of a spring.

The steering wheel should be attached not only to rear-view mirrors, levers, cables, but also to various electrical appliances, which can be purchased together with the body in many places. The devices that look most beautiful are those placed in chrome-plated boxes/cylinders.

You need to know how to make a motorcycle with your own hands as correctly as possible even before installing the throttle handle on the steering wheel. The latter should be made with small turned rubber rings.

Don’t forget about installing turn indicators on your homemade bike. Their absence on a motorcycle can lead to various dangers on the road. You can supplement the classic set of lighting devices (headlight, stop, turn signals) by installing small flashlights near the front headlight. Additional safety will be provided by installing safety arches on a homemade iron horse.

It is important to remember: when making a motorcycle with your own hands, make sure that in the future you will be able to register it with the road control authorities. Any major changes in the design of the bike must be registered with the traffic police/traffic police.

Scooter tuning - intake pipe tuning

The gasoline-air mixture prepared by the carburetor then flows into the crankcase through the inlet pipe. This part is sometimes mistakenly called a manifold, which is incorrect, since this pipe does not collect anything, but only directs the mixture into the crankcase. It is important that the flow area of this part is no less than the size of the carburetor, otherwise there is no point in installing a carburetor!

The flow area of the standard pipes on most scooters is such that you can easily use a 17.5 mm carburetor instead of the standard one. The same cannot be said about 19 mm carburetors! What can we say about such scooters, subjected to grief tuning with the help of 21 or even more carburetors without replacing the intake pipe!? Through tears, we call these “scooters named after the 19th carb”... An anecdote comes to mind: Stirlitz gave the dog gasoline and let him go. The dog ran 5 meters and fell. “The gasoline has run out,” thought Stirlitz.

Scooter tuning - reed valve tuning

As a rule, a reed valve is installed directly at the inlet of the crankcase, also known as a “house” for its traditionally angular shape. However, not all reed valves have the characteristic “house” shape. The following engines use single reed valves as standard:

vertical Honda engines (primarily AF18)
almost all Peugeot engines (Trekker, Speedfight, Vivacity)
vertical Minarelli motors (Yamaha BWS, Slider)
as well as Morini (Aprilia SR 2000, Italjet Formula, Malaguti Crosser, Suzuki Sepia, Address)

It is these scooters that, first of all, require a tuning flapper valve, even when tuning the Sport class. In many other cases, you can easily use a standard valve, but with carbon petals. Of course, if we are talking about tuning of the Racing class and above, a tuning valve is required!

Scooter tuning - CVT tuning

Despite the fact that a variator is essentially the entire scooter transmission system, including 2 pulleys and a belt, in the world of scooter tuning the term “variator” is assigned to only part of this system - the moving (internal) part of the drive pulley. As a rule, installing any tuning part, for example a muffler, is quite simple, but often after installation new tuners are perplexed...

Why did the scooter start to ride worse? The answer is simple - the scooter is not configured. But even when more than a dozen tuning configurations made from weights and springs have been tried, it is not always possible to achieve smooth acceleration at constant speeds. This is where the tuning CVT comes to the rescue. By smoothing out failures in the transmission, it allows you to configure it optimally. Sometimes you can easily do without a tuning variator, but sometimes it is simply irreplaceable!!

DIY scooter with gasoline engine (33cc/4T)

Hello to those who like to make things, I propose for consideration a project for making a homemade scooter. The author used a motor from a gasoline trimmer as an engine for the scooter. An interesting fact is that this engine is four-stroke and needs to be powered with pure gasoline without oil.

The only problem with such engines is high speeds; to solve this problem, the author used a reduction gearbox from an electric motor. The homemade product accelerates to 40 km, and the motor used here is not the most powerful, only 33 cc. If the project interests you, I suggest you familiarize yourself with it in more detail!

List of materials:

– engine from a 4T/33cc petrol trimmer;– chain drive;– gear motor;– brake system for a bicycle;– throttle handle;– bicycle stand;– small wheels from a children’s bicycle;– an old bicycle for spare parts;– profile pipes;– round pipes; – sheet iron.

Homemade manufacturing process:

Step one. Gearbox installation

The shaft speed of the selected engine is too high, and the torque is weak, since the engine used is not very powerful. To solve this problem, we need a reduction gearbox, which will allow us to obtain high torque and reduce speed. The author found the required gearbox in an electric motor, we disassemble it and remake the gearbox. The drive gear here is made directly on the engine armature, so we cut off a piece of the axle and now it needs to be installed on the shaft of the gasoline engine.

The motor shaft has a splined hole into which the trimmer shaft is inserted. We need to make the diameter of the rod cut from the anchor smaller; for this, the author clamps it in a drill and, thanks to the grinder, sets the desired diameter of the shaft. Well, then we drill a hole in the trimmer shaft, cut a thread for the screw, and make a groove in the installed shaft. As a result, we will not have to damage the engine from the trimmer.

The gearbox itself must be very firmly attached to the engine, since this is where the load will go that the engine will transmit to the drive wheel. We will need to make special brackets; we will fasten them with the screws that hold the gas tank on the trimmer, the clutch cover, and so on. We make the brackets from sheet iron of suitable thickness, bend them, drill holes and weld the nuts.

Step two. We weld the frame

Let's prepare wheels for the scooter; for this we will need wheels from a children's bicycle. We install a disc brake on the drive wheel, and also install a leading driven sprocket, the author has it on a ratcheting mechanism, so that the scooter will coast.

Based on the diameter of the wheels, we decide what length and width the frame will be, and then we proceed to assembling it. The author uses profile pipes as material. We cut and weld, and at the rear of the frame we make a fork for the rear wheel. For this we use two iron plates.

As for the front part, the author decided to use a piece from a bicycle. The frame was cut and the forks were cut to the correct length. We weld the frame at the desired angle to the scooter frame and now we have the entire frame almost ready.

Step five. Installing the engine and brakes

The engine needs to be secured securely; we manufacture and weld mounting ears to the frame. Well, then we fasten the engine with the same screws that hold the gas tank and other engine parts.

Be sure to install the brake; we have already installed the brake disc on the wheel. We weld a mounting plate under the caliper and screw the caliper with screws. That's all, after installing the chain, you can start the engine and see what speed the wheel develops.

Step seven. Painting and assembly

We clean the frame well with a brush attachment for an angle grinder, and where we can’t get to it, we work there with a hand brush. For the frame, you also need to cut out the bottom from sheet iron.

The frame can be painted, now everything looks beautiful, and it won’t rust. You can start assembling, install the throttle handle and connect the rear brake. As for igniting the engine, it is highly advisable to place the switch on the steering wheel so that you can quickly turn off the engine if something happens.

Scooter tuning - impeller tuning

If on one side the belt in the drive pulley rests against the variator, then on the other it rests against the impeller. The impeller got its name for the additional function it has - transmission cooling. Tuning impellers have larger blades, allowing them to operate with greater productivity. Considering the low price of this part, we can safely recommend it for purchase. Sometimes, when installed with an appropriate variator, the impeller allows for a larger operating radius of the drive pulley, for example in the case of the Polini kit for the Honda X8R scooter.

Assembling a moped

The assembly procedure itself consists of a simple step-by-step algorithm. This involves following the relevant instructions, which consist of a number of steps:

the frame is first cleared of all present elements;
here it is necessary to prepare a platform for the motor;
subsequently the gas and brake cables are separated;
fuel supply and brake switches are also installed;
subsequently the internal combustion engine is installed;
the next step is to install drive sprockets and wheels;
Next we have to install the fuel supply system;
at the very end, additional auxiliary elements are hung;
The starter and drive mechanism are installed.

Upon completion of this procedure, all that remains is to check the assembled unit for functionality.

Painting

After the device is assembled, you can begin to coat certain structural elements with paint and varnish. It should be noted in advance that the frame itself is painted immediately before the start of full assembly, otherwise the paint may damage the existing elements. In practice, any part is first cleaned of old paint, after which the existing corrosion and rust are removed. Subsequently, the bare metal must be degreased and subsequently applied with primer. The primer is coated in several layers and dried thoroughly, after which several layers of paint are sprayed and sanding and polishing are performed. It is recommended that all removable parts be painted in the same order as the frame of the device itself.

Homemade mopeds

In modern life, such a device can act not only as a means of comfortable movement, but also as an auxiliary element for certain devices, namely:

Quite often, such devices are converted into special equipment for subsequent cultivation of the land.
It is envisaged to use such a unit as a surface transport when combined with a boat.
If necessary, such a structure can be converted from a two-wheeled vehicle into an ATV.
There is also the possibility of using parts of a former moped to equip a small conveyor.

Scooter tuning - belt tuning

The role of the belt in the transmission of a scooter cannot be overestimated. By connecting the drive and driven pulleys, it is the belt that transmits torque from the crankshaft to the gearbox mechanism. As you know, the belt on a scooter is a consumable item and wears out quite quickly. When tuning, the load on it increases, so the wear process accelerates. A variety of manufacturers, right up to the tire giant Continental, offer samples that are more wear-resistant than the standard one.

Rigid Kevlar belts are not recommended for use with a standard CVT to avoid premature wear of the latter. The choice of belt should be approached very carefully, since according to the tests carried out, different belts can work completely differently in the same transmission. And sometimes, without appropriate settings, they can only worsen the dynamic and speed performance of the scooter.

Scooter and tricycle made from a chainsaw

Chainsaws, as mentioned above, are very popular among home craftsmen. They are distinguished by their light weight and dimensions, and in terms of power they are what you need. Today on the Internet you can watch many video tutorials on how to make a tricycle, scooter or moped from a chainsaw . More often mopeds and scooters are made from the Druzhba chainsaw. An old bicycle is also taken, onto which all the parts are installed, including a forward flow muffler.

An example of a homemade tricycle scooter

It is the forward flow muffler that becomes almost the main feature of making a homemade scooter, because you need to know some of the secrets of its installation. The forward flow muffler was originally invented for sports cars. A forward flow muffler in itself already increases the power of a scooter engine.

Air filter

An air filter for a homemade moped or tricycle is also made by hand. First of all, the filter must be reliable. It is recommended to use an oil filter from Moskvich, a washbasin siphon, a metal pin, silicone and a self-adhesive micro-pork to make such an element.

The filter is clamped between the neck of the siphon and the rest of it;
The whole thing is held together with a metal pin, the length of which is selected on the spot;
Place the plug on the metal pin;
We collect everything and treat the cracks with silicone;
We glue a micropork onto the flange of the siphon neck.

Homemade air filter

The result is a quite attractive-looking and very functional filter for any homemade product, including a moped or tricycle.

In conclusion, I would like to remind you that while making a homemade product, it will be useful to watch a video that gives practical understanding.

Scooter tuning - gearbox tuning

What scooterists often complain about, even after a little tuning, is that they cannot reach the maximum speed. After all, when tuning the Sport class, the maximum engine speed increases quite slightly, which means that there is simply nowhere to get a significant increase in the maximum speed. However, the increased volume gives the motor more traction, which allows you to overcome hills at maximum speed, which previously could not be done without slowing down.

A new gearbox, or rather, gearbox gears, will help turn this increase in traction into additional km/h on a straight line. With their help, you can change the transmission ratio, thus increasing the maximum speed. Of course, the engine’s thrust reserve is not infinite, so you won’t be able to increase the maximum speed endlessly!

Plan and drawing of a moped

In order to make a hole yourself with your own hands, you have to prepare first, and in addition find the appropriate manufacturing scheme, which can be done in the following order:

First of all, you can prepare everything you need yourself, but certain skills are required.
If necessary, you can find a suitable scheme freely available on the Internet on thematic websites and forums.
A person can seek help from a specialist who can develop an appropriate drawing.
Additionally, there is the opportunity to select a suitable option from the available elements.

Scooter tuning - clutch tuning

The centrifugal clutch, installed on the shaft of the variator driven pulley, gives the scooter the ability to move away independently as the engine speed increases. Often, when tuning, the scooter receives a fundamentally new character of the engine and, in order to fully realize its capabilities, the clutch must operate at higher speeds. Sometimes this can be achieved by replacing only the clutch springs, but sometimes (as a rule, starting with the Midrace tuning and higher) you have to change the entire clutch. Tuning clutches have pads made of more advanced material, and also often offer more options for tuning - it all depends on the class of the selected product.

When tuning Midrace and above, the load on the clutch assembly is sometimes so high that in order to avoid overheating it is wise to replace the clutch complete with a bell, which is also offered by various tuning manufacturers.

We adjust valves (4t engines).

As mentioned earlier, the engine must be serviced before boosting.
Work that will help improve dynamics includes adjusting the valves. The procedure is suitable for tuning Chinese 4t scooters and other 4-stroke engines. For small-capacity equipment, it is recommended to carry out such adjustments at least once every 3, and preferably once every 2 thousand km. It is also necessary to carry out adjustments after manipulations with the CPG. Before you begin, you need to make sure that the engine has completely cooled down and that you have a set of keys (8,9) and feelers of 0.05 for the intake valve and 0.07 mm for the exhaust valve at hand. You can get to the adjusting nuts by first removing the valve cover. When access to the valves opens, the piston is installed at top dead center. Next, a feeler gauge is installed in the intake valve gap and, depending on the current position, an adjustment is made.

To increase or decrease the clearance, you need to loosen the lock nut (while holding the adjusting bolt), turn the adjustment bolt and, while holding it, tighten the lock nut back. Thus, we achieve a gap when the probe passes into it with little effort. After adjustment, make a full revolution of the crankshaft and make sure that the adjustment is accurate.