Motorized Electric Scooter Converted To Gas

[lowracer]

Jan. 1, 2013
Today was the start of my new scooter project.
Recently I built a pusher trailer for a skateboard (more like a motorized fork) & then modified it to push a bicycle. The bicycle pusher proved pitiful & wore out the driven trailer tire within 10 miles (not enough weight on the driven wheel). It went back onto the skateboard as a weight bearing rear driver & worked pretty well, but where can you go on a skateboard? (I only rode it around my block)
I found a Razor e325 electric scooter being sold on Craigs list for $20 with messed up electronics. The scooter is designed to hold up to 200 lbs & has a heavy duty steel frame & fat 3.00-4 wheels & tires (10"). I'll be doing a conversion to gas power using my tried & true Tanaka PF3300 w/ Pocketbike 5:1 transmission. Project goal is to be street legal in my State (<50cc, <2 hp, <30 mph).
I ripped the electronics out & removed the 55 tooth freewheel. I threaded on a 18T BMX freewheel I had laying around. Now I just need to mount the pocketbike transmission using the uprights of the scooter frame above the rear tire.
Here are some pics of what it looks like so far.
-Lowracer-

 

[lowracer]

Here's a shot of the 18T freewheel installed (scooters must share the same threading as bicycles). I also hooked up the rear brake with new cables and lever & throttle cable & lever. Unfortunately I gotta go back to work tomorrow (vacation is over) & wont have the free time to get the engine mounted quickly...
-Lowracer-

 

[16v4nrbrgr]

I think you'll really like the result, Razor makes really good frames IMO.

 

[lowracer]

16v,
The frameset is solid.
Got so much lighter with the battery compartment & electric motor removed.
I've removed the Tanaka 32cc from the motorized skateboard project & am contemplating how to set up my mounting.
Bought some new Sawzall saw blades & a new 5/16 drill bit today in preparation for the festivities ahead.
-Lowracer-

 

[lowracer]

Here are a few pics taken this morning.
I mounted the 5:1 pocketbike transmission to a piece of 1/4" angle aluminum. This piece will eventually be cut down (towards the rear of the scooter). I've drilled 2 holes thru the front part of the 1/4" mount & thru the scooter frame cross member & bolted with 1/4" bolts & nylocks. I vice-grip'd a piece of steel bar to both the freewheel cog & transmission cog to insure correct chain alignment. I will probably reinforce the scooter frame member (rear fender mount), with some additional 3/16" steel bar and then some diagonal bracing from the axle dropout to the upright.
Will post more pics as I find time to complete the mount.
-Lowracer-

 

[lowracer]

Here's what I got done this morning between 7am-10:30am.

I still have more to do & I made a list.

1- install longer engine mounting bolt
2- make 1 front transmission mount
3- reinforce left side of rack
4- install throttle cable (50' housing on order)
5- install chain (& derailleur?)
6- install foam grips (on order)
7- test rear brake lever (v-type) & keep or switch to non-V
8- install new rear tire (on order)
9- cut & drill platform beams (under floorboard reinforcements)
10- cut & drill wood deck platform (buy griptape?)
11- cut rear fender & mount (keeps pants out of rear tire & chain)
12- install expansion chamber (running forward along & under left side of platform)?
13- reinstall engine tilted counterclockwise one position (if using expansion chamber)?
14- cutoff battery mounting cage (under scooter)?

-Lowracer-

 

[Mike B]

Here's mine;

It was gas to begin with, but the motor was cutting out so I put a 33cc Tanaka on it.

Works good now -

 

[lowracer]

MikeB,
Nice scoot!
I've geared mine to max 28-29 mph...but I'm not sure how it'll handle at those speeds?
What are your impressions on the low & high speed handling of yours?
Thanks,
-Lowracer-

 

[Mike B]

This is geared low, so 20 is as fast as it goes. But it pulls great.

Handling? You are joking right? These things are as squirlly as it gets - I got this one because of the big wheels. I rode one of those small wheel models and near fell off.

Like all my bikes, it has a basket and a lock, so I can run errands on it.

 

[lowracer]

MikeB,
I got the scooter together enough today to test drive it & let my daughter ride it around the neighborhood. She's 9 & didn't want to stop riding it....lol
I started knocking some items off of my 'To Do' list.
- Bought the two bolts I needed to mount the engine & transmission to my motor mount.
- Installed the throttle cable
- Switched rear brake lever (V-brake levers dont work well with band brakes)
- Installed the chain & rear derailleur (properly routed chain around rear rack)
- Cut, drilled & bolted metal for temporary platform feet area (will go w/wood probably)

I still have more to do to it, but its rideable & lots of fun.
Its squirrelly compared to my refined MB's, but alot more stable than the motorized skateboard project I recently built. I could go far on one of these but will I?
probably not...
Good thing the chain didnt come off once! I think I got chain mgmt under control now...
-Lowracer-

 

[d_gizzle]

Looking good low!


MikeB,nice. Very,very nice.

 

[d_gizzle]

Looking good low!


MikeB,nice. Very,very nice.

 

[lowracer]

Thanks d gizzle
Was a nice build for $20.
I had the engine & trans from previous bikes & lots of spare parts/metal for the construct...
-Low-

 

[d_gizzle]

I figure by the time I'm doing my 4th build(I'm about to start #2) I shouldn't have to buy anything. That doesn't mean I won't buy things,just that I won't NEED too.

 

[lowracer]

d gizzle,
I did order a new rear tire w/tube on eBay for $23 since the previous owner of the electric scooter liked to skid the rear tire.
I'd still like to own a 'real' scooter, but this one is nice & quiet and I think my daughter pretty much claimed it today as her's....lol
-Lowracer-

 

[lowracer]

Today (Sunday) it rained so I got to get most of the rest of my 'To Do' list knocked out on the scooter.
- I reinforced the left side of the engine rack with metal.
- Took a link out of the chain for improved rear derailleur position
- Mounted a chain shield
- added a front transmission mount
Now, I just need the foam hand grips (on order), new rear tire (on order) & cutoff the under frame battery cage.
Before the rain started, my daughter, son & I got a few laps around the block on it & this one is a keeper...
Here is a pic of it today w/chain guard detail
-Lowracer-

 

[lowracer]

Got the foam grips installed.
Will hang onto the rear tire/tube for when it badly needs replacement.
Heres a pic of the 'business end' of things
Cheers,
-Lowracer-

 

[lowracer]

My kids have been taking turns riding this scooter all over the place & having a blast...
What a great project this was.
Last thing I did to it was took apart the headset & regreased the bearings & races...so smooth now.
I got a business associate bringing to work on Monday a gas powered scooter that his son doesn't look at anymore. He just wants to get rid of it & probably doesn't want much or anything for it.
I think I'll pick it up, tweak it & have 2 of these things in the stable for both my kids to rip around on & not have to take turns...
Here's a pic of the foam grips installed & the top to bottom...
-Cheers-
Lowracer

 

[lowracer]

I wanted to change my gearing to give more acceleration & less top speed.
I took the stock 4 bolt flanged freewheel that came with the Razor & unbolted the #25 chain sprocket since I run std. bicycle chain 1/2" x 1/8" (#410). I had a 22T 4 bolt MTB sprocket in my spare parts bin (64 bcd) looking like it would line up perfectly with the existing freewheel holes. I had to cut away some extra aluminum material around each hole in the sprocket with my handy sawzall to get it perfectly onto the flange. Bolted right up & allowed me to go from 18T to 22T which effectively changes the top speed from 28mph to 23mph while giving much better off the line & roll on acceleration. These scooters in stock electric form do a max of 15 mph and feel very stable up to ~20 mph. Anything above that makes for a squirrely ride on normal roads. I was going to thread on a 5 bolt ACS Crossfire flanged freewheel I got for a different project with a 32T chainring, but that would be too much of a gear jump & only max out @ 16 mph.
-Here are some pics-
-Lowracer-

 

[d_gizzle]

Looks like a winner low!