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Old 08-11-2013, 09:54 PM   #1
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Default my big bore kit scooter build, my first engine overhaul.

hey all. so heres the story. back in 08, i bought this chinese scooter (honda gy6 copy) by 2009, i was sick of 30mph. so i bought a 72cc big bore kit, ruined the rings and before i had cash for a new set of rings, i got my license. needless to say the scooter sat in about 500 pieces for over 4 years. after realizing that i have to work almost 2 hours to break even on gas to go to and from work, it gave me the push to rebuild the scooter and ride it to work. (and save some wear and tear on the car during nice weather anyway)


sooo. i bought a 100cc big bore kit.

here is a pic of the old 50cc piston in the new cylinder sitting on the new piston.

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after rebuilding the top end, i replaced the weights in the variator so the scooter could take off at a lower rpm, also adding a higher top speed. (cvt transmission)

after all that was done, the engine was ready to reinstall.

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after that, i fixed my throttle cable with some bicycle brake cable, a drill bit a piece of scrap metal a grinder and some lead. had to make my own ends, because i didnt want to wait on china to ship me a new one that was just going to fail again. (the scooter only has about 3,000km on it. that gives you an idea of why i didnt want to get another cheap *** chinese cable and instead opted to do it the hard way)

before i did this, i had ghetto rigged this thumb throttle out of a bicycle brake handle and some cable clamps. even at age 15 i was rednecking .

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after i had the scooter up and running, i decided i could use some tunes for the 40 mile per day ride. -this is where my redneck side comes out-. the pics show the stereo without the glovebox lid. i have since installed it back on.

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if anyone was interested, those cheapo walmart "hd" speakers sound fantastic. here is a link to em

after all that was said and done, i took her for a 30 mile ride, and she did fantastic. it hits 50mph on flat ground no problem, and going down a hill i buried the needle. id estimate i hit about 60. needle only goes to 55mph though, so i cant be sure.






ill upload a video as soon as i find my helmet and can strap my camera to it. (no helmet law in indiana).

i prefer a helmet myself because i cant stand the sound of wind in my ears (apart from the obvious reasons) but i cant see dropping another $200 when i know i already have one. its just a matter of finding it after moving 3 times. lol


thanks for reading guys. im pretty proud of my little project. its my first ever engine overhaul. lol
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Old 08-12-2013, 08:33 AM   #2
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cool project. i would rather wear a helmet too, i go to oklahoma frequently and the fools there dont wear helmets even when riding a rice burner going a hundred down the highway. talk about dumb
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Old 08-25-2013, 11:23 AM   #3
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update: scooter still runs great, i finally fixed the glovebox where it closes by cutting a hole in it. this way i can also adjust the stereo while riding. i have parked it for now, because i did a bbk install on a friends scooter, and realized mine is missing the spring for the chain tensioner. which means when the bran new chain on mine wears in, i might have some timing issues. today i plan on going to ace to see if i cant find one. lowes and menards i had no luck finding a 6" long spring that fits inside a hollowed out 8mm thread.
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Old 08-25-2013, 10:54 PM   #4
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Old 10-26-2013, 05:15 AM   #5
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nice rebuild I am in the process of looking for parts for my little sl70 and I found a 125 CC motor for 200 that I am looking at to put back and forth to work on.
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Old 01-11-2014, 08:46 PM   #6
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Nice Work Jason! I bet it goes faster now..nice to have tunes as well !!!
A few years ago I restored a 1972 Yamaha 75cc 2 2 stroke oil injected, 2 person did 60mph
in 3rd gear with 2 on it.
Very strange shifting pattern coming from riding motorcycle for decades onto this thing..
had to have a card that read gears- 1 up two down..yeiks...sold it cause I couldn't get use to it..and was afraid i was going to blow the trans or motor!

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