TaoTao 50cc to 150cc engine swap Part 3

Introduction

This tutorial provides a step-by-step guide on how to successfully swap a 50cc engine for a 150cc engine in a TaoTao scooter. The information is based on hands-on experience, ensuring reliability and performance. Whether you're upgrading for speed or efficiency, this guide will help you navigate the engine swap process effectively.

Step 1: Assessing Your Current Setup

• Inspect the existing frame and components of your TaoTao ATM50-A1.
• Ensure that the frame is structurally sound. Look for any signs of wear or damage in the welds.
• Consider adding extra cross members for additional support; this will enhance stability during operation.

Step 2: Gathering Necessary Parts

• Collect all required parts for the engine swap. Key components include:
  • 150cc long case engine from a 2012 VIP PowerMax
  • 2012 VIP 150cc factory exhaust
  • 150 VIP frame mounts
  • Stock clutch and belt from the 150cc engine
  • 12-inch tires and wheels from the VIP 150
  • VIP 150 throttle cable and speedometer cable
  • 2012 Taotao Thunder triple tree
  • 150cc cone air filter (the stock air box is often too restrictive)

Step 3: Removing the Old Engine

• Disconnect all electrical connections and fuel lines from the existing 50cc engine.
• Remove the old engine by unbolting it from the frame. Take care to keep track of all hardware for reinstallation.

Step 4: Installing the New Engine

• Position the 150cc engine into the frame and align it with the existing mounts.
• Securely bolt the engine into place using the frame mounts previously gathered.
• Ensure that the exhaust system is properly aligned and secure.

Step 5: Upgrading the Front Forks and Suspension

• Replace the existing front forks with those from the VIP 50cc or Taotao Thunder to accommodate the larger 12-inch rims.
• Install the new front brake caliper if necessary, ensuring compatibility with your new setup.
• Test the suspension for leaks and ensure it operates smoothly.

Step 6: Adjusting the Throttle and Speedometer Cables

• Install the new throttle cable from the VIP 150cc to ensure proper operation.
• Connect the speedometer cable and verify it functions correctly with the new engine.

Step 7: Testing and Safety Checks

• Conduct a thorough inspection of all welds and mounts. Ensure complete welds are in place to prevent structural failure.
• Perform a test run. Start with low speeds to check for any unusual noises or issues.
• Gradually increase speed while monitoring the vehicle’s performance.

Conclusion

By following these steps, you can successfully complete an engine swap from a 50cc to a 150cc on your TaoTao scooter. Ensure all components are secure and functioning properly for a safe ride. Always prioritize safety and reliability, especially when modifying your vehicle. With proper execution, you can enjoy enhanced performance and speed on your scooter.