How to split a AF16e case for noobs. Plus 120cc install

[Limp1144]

Yes belt on wrong will do that everytime. I got a eletric impact from harbor freight for 39.00 have had it for 8 months no problems.

[eclypse]

Yes belt on wrong will do that everytime. I got a eletric impact from harbor freight for 39.00 have had it for 8 months no problems.

Good to know!

Yeah my 88 Elite SA50 LX sat in my parents garage for 20 years with the motor in parts. All because my old man could not figure out how to get the piston in with the new rings on.

late last summer we got the rings on (cause of the info on this forum). The scooter sat there all winter on a table unitll late spring. We got that motor all back together and on the scoot in 6 hours.

I thought it was late that evening around 9:30Pm but my old man said lets put some gas in it and some oil and fire it up! I was in shock and had no idea we would be starting it that night. It started finally and i took it down the street and it never shifted. Thought, great we screwed something up.

Good to know its not that serious! lol.

God i cant wait to fix that belt and fire it up.

[Limp1144]

Ok got off my lazy @SS and went to buy the proper porting bit from Northern Tool $8.68. Had the block bored in 45 minutes now the crank turns nice and smooth with no problem, binds, or kinks. Now that the die grinder as ate up a good amount of bolt holes i am going to run 3 bolts thru the case to a nut on the other side. Will post pics tonight

[bakaracer]

lets see the pics of the case.I did warn you you not to use the die grinder.I speak from years of experience of witnessing people using different tools to cut the case and same result aways happens.post a pic of the case so that way we can see if there is a fix to the damage.

[Limp1144]

I am going back thru to polish the whole case and smooth it out. But not to bad for my first time.
Gonna use lots of honda bond to make an air tight fit.


P.S. dremel stopped working after 5 minutes so i bought the die grinder

[bakaracer]

HOLY CRAP! you cut the s*** out of the case.even if you put a longer bolt and nut on the otherside,you are still going to get air leaks from the bolt and bolt hole.you might have to honda bond the bolts in to try and make it air tight but thats an iffy on that.

[Limp1144]

Yeah took alot of cutting but i will honda bond the bolts to make a good seal
might jb weld it

[Limp1144]

To everyone that think i cut the SH$% out of my case is on top the standard crank and below the 52.6mm crank. guys i did not cut the case anymore than i had to. Please show some respect
41.4mm crank

52.6mm crank

[bakaracer]

hey remember when I told you the clearance is around 0.025in.I think thats more than that.the clearance is so close it almost will look like it touches when done right.if your in the thread area thats to much.so next time you do another case,make the dummy bearing,mark the crank on the case and cut on the inside of the line and double check with a feeler gauge.Thats ok its your first case cutting experience.lesson learned,I hope.

[Limp1144]

Hey guys. I feel like i am being flamed here haha. I made a dummy bearing and marked the crank with a sharpie. also i sharpied the crank floor. .025" the metal would be to thin to hold up good. This crank rod was hitting a few places on the case so i needed to shave it more

[Limp1144]

Yah guys more fitment issues. The 54mm needs a minute amout of cutting to fit what a relief.
Cvt side

front of case

Flywheel side

[burnt_toast]

cool, interested to see how it performs

[veedubh20]

that too much to cut crankcase made fit big stroker crank .
Motor will blowup anytime.

[Limp1144]

Guys it would not fit in there till i cut it this much. I did not cut extra. Today i am cutting the top of the block for the cylinder. drilling and tapping 3 case bolt holes thru the case with a nut on the back. I watch a dio speed demon video on youtube today. Guess what he had to cut into the bolt holes as well this is a 52.6mm crank. He install a 52.5mm crank SEF, which requires you cutting the case floor 1 mm not ruima. If it blows up i will put back together again till it doesnt blow up. Motor will be fine. Its just a little 2 stroke

[wiguy05]

I watch a dio speed demon video on youtube today. Guess what he had to cut into the bolt holes as well this is a 52.6mm crank. He install a 52.5mm crank SEF, which requires you cutting the case floor 1 mm not ruima. If it blows up i will put back together again till it doesnt blow up. Motor will be fine. Its just a little 2 stroke

I've also watched this guy's videos and was less than impressed. He had some good points, but also so completely retarded ideas.

(See dual inline carburetor setup )