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Post by 49ccdrew on Jan 12, 2021 0:09:30 GMT -5
Ever since I got into scooters, I’ve always wanted a Ruckus, but not the stock GET engine in them. Yes, I know you can get some extra speed and power out of them, but that time and effort making a GET faster could be better spent swapping in a two stroke Minarelli style engine. Firstly, I needed a Ruckus to build, and after looking at Facebook Marketplace and Craigslist, I could not find a reasonably priced Ruckus that fit my needs. I decided that I could build a Ruckus from scratch by sourcing the front aluminum frame, as well as the rear tube steel frame. This is what I started off with, a Honda Metropolitan frame, which shares the same front frame as a Ruckus. I traded a Polini GET variator in exchange for this frame from my friend. i.postimg.cc/DyPngmPs/A5-E8-A9-C3-7-A68-4-AAA-8-D27-054-EE8-D8-CBC9.jpgShortly after I found a Ruckus rear frame for a good deal, I got this: i.postimg.cc/HnC10CJB/9573-A6-BA-702-A-4-EED-9-C46-092-D59-FCEF46.jpgPlease pardon the mess in my garage at the time. You can also see the Bugeye Zuma 50 engine waiting to go in. However, this engine did not stick around for long. |
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Post by 49ccdrew on Jan 12, 2021 0:28:00 GMT -5
I took a month long hiatus from this project, as I got busy with college and moving into a duplex. I eventually got the Zuma engine mounted by using the stock Ruckus subframe engine mount with some modification. I quickly ran into a problem: i.postimg.cc/6qQLm8G3/25-D967-FC-9-E7-E-4-F8-E-835-E-9631394-D4-D5-A.jpgThe frame gusset that braces the frame on the shock side, was in the way of the CVT case, and interfered no matter what length shock I put on to adjust the engine angle. I then cut out the gusset, and fabricated a stronger one to be welded on, away from the engine case. Unfortunately, I did not photograph this process, nor did I photograph the build until this picture: i.postimg.cc/SNNtBspc/256-D4991-904-B-4-A36-8-B3-D-D1-DE76-B8-AFE8.jpgIn this picture, I had sourced a variety of parts, such as a Ruckus stem/triple tree, NCY disc brake forks, Aprilia SR50 Minarelli wheels and tires, free handlebars, gas tank, fender and seat frame. After getting the Zuma engine mounted, I ran into another problem, and that was a horrible shock offset. Because the Ruckus never was intended to have a 2T Zuma engine in it, the top shock mount was offset about an inch from the bottom, resulting in a weird shock angle that could not be compensated with offset shock risers. This meant that I had to redesign the shock mount, and thus resulted with this: i.postimg.cc/pd6FLs92/C0463-E60-26-AC-4-A3-F-BD8-D-A5-C898-D0-B209.jpgIt has since been welded, and now the Yamaha Vino 2t shock I am now using can compress and expand correctly. |
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Post by 49ccdrew on Jan 12, 2021 0:42:48 GMT -5
Where I lost all motivation to continue, was when I attempted to fit the fan shrouds I bought for the motor, only to learn that the Ruckus frame had much less room for the stator side shroud to clear. To fix this, I would have to offset the engine to allow room, or fabricate an entirely new engine mount to move the engine back some, and allow extra space for the fan shrouds. Because of my limited garage space and inaccessibility to a welder, I shelfed the project, and focused on other hobbies. During that time, I sold the wheels and the Zuma engine to friends that needed them, thinking that I would never get back to this Ruckus build. However, after surfing Marketplace, I found a 2004 CPI Oliver City 50, a scooter with a clone Minarelli engine and 12” wheels. I scored it for $150, with a title! i.postimg.cc/Cxfy21jm/3424-A3-D3-1-D88-456-D-8-BFB-FF03-CAAC8-CC1.jpgAlbeit looking decent on the outside, the bike was hiding many broken, cracked and busted body panels and tabs, and the fuel tank had gone rusty from collecting rainwater outside. I decided to revive my Ruckus by cannibalizing the engine and wheels, again resulting in this: i.postimg.cc/X7MTt3Y8/F12-EBD7-F-3-C03-4114-9903-54663-C3-B7-C26.jpgNow that I have a CPI long case engine in place of the Zuma engine, my fan shroud clearance issue went away, and now I have beautiful shroud fitment. i.postimg.cc/mkcVrcZn/BBFEAADC-596-C-4576-AF18-32438943-A3-BD.jpgThis is where the Ruckus now sits, after six months since I started it. I wish I had photographed more of my journey to this stage, because a Honda Ruckus is one of the most modifiable scooters out there, yet a two stroke Ruckus swap is a seemingly new avenue to explore. I hope you join me in completing the rest of my journey to building a fast, two stroke Ruckus. I have plans for this bike in the future, and now that most of the bugs are worked out, I can now progress farther. |
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Post by 49ccdrew on Jan 12, 2021 0:52:10 GMT -5
Oh! One thing I forgot to mention was the intake setup. Due to the location of the engine in the frame, the standard carburetor and intake location found on Minarelli engines will be impossible to do, so I have chosen a rear facing intake found on the Vento Zip and the Keeway Hurricane. rover.ebay.com/rover/0/0/0?mpre=https%3A%2F%2Fwww.ebay.com%2Fulk%2Fitm%2F253897854240This intake relocates the carburetor to where it now sits behind the CVT side engine mount, and the starter motor. This intake will accept any carburetor with a 23mm spigot mount (Dellorto PHBG, PHVA, Polini CP, etc). It also has a 19mm ID on the opening, and if you want to run a 21mm carburetor, the intake would have to be opened up with a dremel or rotary tool. |
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Post by jbjhillbilly on Jan 12, 2021 1:56:39 GMT -5
Very cool!
I know how hard it is when you lose momentum on a build. But don’t get discouraged. Just set a little time aside and GET to it (easy to say, right?)
2t engine swaps were not uncommon before the GY6 craze. Mojo Customs still makes a mount.
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Post by aeroxbud on Jan 12, 2021 2:31:09 GMT -5
Very cool build so far.
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Post by CrankingWithCG on Jan 12, 2021 5:02:41 GMT -5
Hell yeah! Clean lil swap man 🔥
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Post by 90GTVert on Jan 12, 2021 15:41:12 GMT -5
 Nice job so far. The ability to use a rear facing intake is desirable with high output Minarelli builds. Most of us have to go and buy or build a different subframe to do it.
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Post by 49ccdrew on Jan 12, 2021 22:29:43 GMT -5
Very cool! I know how hard it is when you lose momentum on a build. But don’t get discouraged. Just set a little time aside and GET to it (easy to say, right?) 2t engine swaps were not uncommon before the GY6 craze. Mojo Customs still makes a mount. It never hurts to step back and take a break. That way you can come back with fresh ideas for solving an issue or obstacle. Thank you all for the compliments and welcome, I look forward to contributing to this forum. As of now, I am waiting on simple parts like a brake caliper mount, master cylinder and handles. I am eyeing some new plastics on Partzilla, as well as a seat on eBay. My goals now is to get a nice rolling bike before I turn to engine upgrades. I am also toying with the idea of making a simple wiring harness, or modifying a harness from a Yamaha Zuma. I have the CPI Oliver harness, and it is in good shape. However, it had a factory alarm system, complete with a speaker and immobilizer. I’ve still got plenty of time to decide. |
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Post by imaijahnation on Feb 1, 2021 13:55:40 GMT -5
Nice work.. I’m planning on doing the same soon.. I have the mojo customs mount kit and a stock Honda ruckus was planning of putting my 08 zuma motor in to the ruckus... interested on the harness as well that’s what I was kinda worried about.. keep up the beautiful work..
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