End Gear Replacement "tips"

[pdaddy]

Well boys and girls !!

I know we have some speed freaks here, and i know alot of people have checked out those "end Gear Replacement gers".

As some of you know i bought a set from Taiwan, see my thred ----> scootdawg.proboards59.com/index.cgi?board=questionable&action=display&thread=1156352058 ..

This is just some good info for the lonley speed demons who are thinking on doing the same mod as I done !!!

-- First off, youre acceleration will decrese, but top speed will offcourse come up. More info will be added in a day or two, need to put the scoot together first.

-- VERY important, BE SURE TO HAVE ACCESS TO THE RIGHT TOOLS. An gear removal clamp is out of the question, dont even think about it !!!
Luckely i have a friend that works for Volvo Aero and have access to the right stuff.
You will need a hydrolic press, a blowtorch or oven and some sort of coolant. These aids are just to make life eazy for you when installing the old gear on youre new axle.

My buddy didnt have a hard time getting the gear off (he preheated the gear and only the gear that was going to come off) , but putting it on is another mess. He froze the axle to -70 celsius and heated the gear to about +300 celsius (cooling the axle to make it smaller and heating the gear to make the hole bigger).

But pressing the gear on the axle is the most difficult part, it's VERY important that the gear and axle are paralell. If not it wont go on perfectly and get stuck, mine were no big hassle cause of a pro making the job .

The result will come soon.

My scoot is a 125cc, top speed about 85 km/h, great acceleration.
Got some info that this 16/37 gear kit will improve the speed about 20-30 km/h in the best case.

Guide on how to remove end gear ...

- Remove exaust
- Remove Rear wheel
- Remove Air filter (not needed but helps)
- Remove Variator/clutch cover
- Remove clutch (press it together so belt is as far in as possible, that way you dont tneed to remove variator.
- Drain Gear oil
-Remove screwes that keeps end gear in place)
-give the rear axle/cover a decent wack and remove the end gear cover. Be carefull with the gasket, it can be stuck so use a flat screwdriver to jently get it loose.
-Remove the big gear at the right (it's seated on the rear axle with splines)
- remove central gear kit (two gears seated together)

Then it's just get to work trying to replace the gears ..

Here's some pics for those who cant read or understand my Swinglish

This is how it looks when the end gear cover is removed.
Gear on the right is in the replacement kit (mounted on axle with splines.
Middle doubble gear on the left, just the axle on that one in the kit (press fitt)




depending on luck it can come off either with gears seated in the scoot or in the cover. Here's a pic of when it's in the cover, first time you remove it it's the way it will come out. but if you dont give the rear axle a wack, the gears will be seated in the scoot.


Well more to come when i have tested the scoot.

BR

Marcus

[somecallmetim]

Thanks for the pictures, they are really clear. You may or may not actually get a higher top speed. If your top end is limited now by RPM, then you will, but how fast your scooter is ultimately capable of going is determined by how much power it puts out. You can gear it to do 90 MPH at redline, but it won't do it unless your engine is making enough power to overcome the drag at 90 MPH. Gear it too high, and you could lose top end, along with acceleration. My scooter is geared so damn high that it only turns 6000 RPM at 60 MPH, and takes forever to get there. I could get more speed and more acceleration with lower gearing for more RPM.

[pdaddy]

somecallmetim said:

Thanks for the pictures, they are really clear. You may or may not actually get a higher top speed. If your top end is limited now by RPM, then you will, but how fast your scooter is ultimately capable of going is determined by how much power it puts out. You can gear it to do 90 MPH at redline, but it won't do it unless your engine is making enough power to overcome the drag at 90 MPH. Gear it too high, and you could lose top end, along with acceleration. My scooter is geared so damn high that it only turns 6000 RPM at 60 MPH, and takes forever to get there. I could get more speed and more acceleration with lower gearing for more RPM.

Well mine are not RPM limited at all, at top speed mine revs about 7900. But downhill or a slight down it wil lrev 8200 max.,
Ao i think it will be able to go abit more. I could always put a sport filter and rejet it for some more umpff ..

You want my used gears m8

M
M

[scooterollie]

Great job pdaddy! Your projects make for interesting reading. Thanks for sharing.

[pdaddy]

scooterollie said:

Great job pdaddy! Your projects make for interesting reading. Thanks for sharing.

Your wellcome !!! All of you guys.

the plessure is all mine

M

[Admin]

Absolutely great post! Pictures speak a thousand words.

[Aaron]

Yet another Karma for our resident Crazy Swede mechanic!! Thanks for your efforts man!

Aaron

[pdaddy]

Thanks Aron ;D

Lee, i could make a better guide, i have like one gazilion picturs in my cam.
Would have been cool if i had been able to take pics of the gear removal and pressing on the new .

Tonight it all will be in place for a slow ride down the street, very eager to se the final result.

M

[pdaddy]

No rewiev today

Im so angry right now, really pissed at me self ......

When i was on my way to take the scoot down from my little platform i slipped, scoot started going down and i lent to the left. The freaking scoot fell on it's way down to the left damaging alot of stuff

Im almost crying right now, this is fu**ng amazing !!!!

-Left rear mirror snapped from the brake, glass broken
-Left blinker glass broken
-Front lower cover broken
-headlight adjustment bracket broken
-headlamp cover cracked
-front wheel splashcover mount cracked
-Alot of mounting screw holders in front kover snapped

I guess it's time for plastic padding or JB weld, When i have the stuff mounted i will test it.
Going to look for scooter covers for Boatian scoots, they look the same almost, wounder if they mount the same way though.

This Suxxxx so much, i really feel like puking right now

M

[sussexscooterhead]

I'm really sorry to hear that Pdaddy.

Good luck getting everything back together.

[somecallmetim]

Sorry to hear about the scooter damage. I was really anxious to hear how the new gears worked, too. Hope you get it all straightened out and back on the road soon.

[pdaddy]

NEWS UPDATE !!!!!

Well scooter friends, now i'we tested my red little beast..

Let's start with the feeling when i first hit the throttle..

Didnt feel like any power outage at low speed to medium, acceliration almost improved it felt like.

My top speed before the mod was about 85 km/h with good condition (wind, road etc), and i did not always get up to that speed. My regular speed were more like 80km/h .

Now after the mod the scoot get's up to 80 very smooth and fairly quick (need to time it). I hit the 90 mark at about 600 meters and the RPM is'nt high. The sad thing is that it's dark and i cant see my tiny tach display, but i will check that tomorro.

In slight downhill (300m) with a straight befor it i came up to 95,4 km/h .

Some people might be abit dissapointed, but im not. The RPM is much lower, i can irretate car drivers by being up there ass without problem on smaller roads.

The most importent thing to note is that i HAVE NOT rejetted mine or put any open air filter on it, nor have i any aftermarket exaust.....
I'm sure if i just replace those stuff it will go up to 95 without probs on a straight.

When the sccot was cold i had no probs doing wheelys, but i was abit afraid cuase i almost went over the first few times. More torn on the back wheel than befor, so i got surpriced ;D .
But after some riding it didnt want to do wheelys, i guess my clutch were to hot and it slipt. Cuase if i let it rest for 2 mins it worked .

So my conclution is..

If you have a 125cc hotted scoot or above and want more top speed.. Go ahead !! what are you waiting for dumbass, make a order ;D *LOL*

I will be doing some more upgrades, clutch, exaust, filter.. Also thought of going "nudebar", but that will make me loose top end cuase of not as good Aerodynamics.

cheers m8

Im a happy camper yet again

M

[scooterollie]

pdaddy;
Sounds great and loads of fun! Congrats on the successful upgrade.

[pdaddy]

Thanks m8 ..
A new clutch might be heading my way in a week or so, i have a free bee to collect .
Very tempting to get a exaust at the same time, first i will check the dia on the pipe on a regular 50cc. But i think it's the same as mine, and then the upgrade will be much needed.

M

[pdaddy]

Sooooo, now i got some RPM answers...

Befor i said max were like 8200 downhill.
Now we are in the 6800 range at about 90 km/h .

In other words there are some speed to catch there, but that needs some adjusting.

I will change to lighter rollers and see what diffrence that could give me. Have some 8 gram sliding rolelrs here, going to take 3 12 ers and 3 8's to get 10 gram.
More rollers will arive in the near future

M

[Darthchile]

pdaddy, which was the ratio of hte original gears in your scoot?

[pdaddy]

I had a 13/40 gearing.. new one was 16/37.

Im down in France at the momen, so im not checking the forum that often.. Them cheeseaters down here are a pain in my ass, high speed internet at the hotell is a killer $$$ wise, so bad word them !!
And they dont understand sh!t, i say i want my steak cremated, and still i get it bloody and almost moving on my plate .. ghaaaa.

M

[Darthchile]

Thanks pdaddy, that is the same ratio that comes in my Vento from Factory.

Although I have to considerate that topography is quite iregular where I live, so there are a lot of hills, so loosing strengh will be counter productive for me.

I guess I'll just get a set of gears and test it.

[pdaddy]

darthchile said:

Thanks pdaddy, that is the same ratio that comes in my Vento from Factory.

Although I have to considerate that topography is quite iregular where I live, so there are a lot of hills, so loosing strengh will be counter productive for me.

I guess I'll just get a set of gears and test it.

Go for it m8..
If you have a 150cc scoot i think you will be better off than me.

When some parts arrive here, i will change to slightly lighter rolls and a new exaust.

M

[ooopseyesharted]

Hey pdaddy,
how is the scoot runnin?

[pdaddy]

ooopseyesharted said:

Hey pdaddy,
how is the scoot runnin?

Pretty nice m8 !!!

New exaust will arive any day now + a race clutch, springs and rollers ..

M

[ooopseyesharted]

You better give us an update.......with pics!!!!!

[Admin]

pdaddy, you da man!

[pdaddy]

Thanks Daaawgs !!

I try to keep you guys happy

I will surtenly make a new thred about the racing clutch, but keep posting results here offcourse..
Only problem now is that the temp is low at night + it's damn dark to.. 8-12 celsius and dark at 19:00.

M

[Darthchile]

Hey pdaddy, I've been using these 16/37 for a while now and I'm going back to stock. The topography here is quite irregular, and on very steep hills the scooter has a hard time pulling up, if I have to stop right in the middle I'm fried!
Maybe if I could get a lower ration, like 15/38? right in the middle.

[pdaddy]

OK !!

What kind of scoot do you have ?? cc etc.
My 125cc cant really get the most out of the gears, but im going bigbore with a 59mm kit so i guess it will be a big diffrence after that change.

M

[Darthchile]

Well, I have a Phantom R4i, 150cc. Big Valve 59mm head installed. High Flow air filter, jetted the carb up to a 127.5 main jet (originally 115). Racing muffler. Racing CDI/Coil and Iridium spark.
On flat land it moved really nice, but where I live there are very steep hills, so the scoot was having a really hard time there.
Actually, last week the crankshaft broke, I had to replace it, so I installed the stock gears again.
Top speed is not that much, 55, that's what the scoot can doo at max revs, but then again, you won't find much roads you can go over 55 downhere, so beter the extra torque than such a high top speed.
It spoked me to go over 65 anyways. At least in a scooter.