Zuma to 460cc piaggio engine swap.

[Zuma500]

I've been working on this project for about a year now, I have a 460cc piaggio, single cylinder, 4 valve single cam, four stroke scooter style engine. This is going onto a Zuma frame, and I've done mock fits and measurements, and it will fit well.


Right now the project is stalled right now due to limited funds. The engine was designed for fuel injection, but given my limited knowledge on that, I decided to go the carburetor route. I had a 40 mm lectron, that was perfect for the project, but I regrettably had to sell it at a large loss. Now I'm searching for another carburetor, more affordable, to get the engine up and running temporarily.


The ignition is a hall sensor based programmable ignition, made for 2 strokes, but it will work in a lost spark cylce. It's battery powered, and has good spark intensity. I plan to use the existing stator to charge the battery, but because I could not find the stock electrical system ( it's an overly integrated mess, with loads of security features, worse than a car) the stock magneto is not being used, I'm just leaving it be.


To mount the engine, I need to get some frame welding done, with lots of reinforcing. I might mount it as a hardtail, because the frame is so light compared to the engine ( <200 pound frame.with a >120 pound engine. If I decide to add rear suspension, I have the stock rear shocks. The original mount is odd, 3 mounting points, I can't really figure it out, even after looking at the manual.


I know it can be done well, as I got the idea from another guy on zumaforums, who put a 400cc Bergman, onto the same frame I'm using ( Zuma 50) I'm sure the frame is strong enough, this isn't going on the highway anyway ( although it certainly could).


So, I have all the parts needed ( minus the carburetor ) and the challenge will be programming the ignition curve, and finding a suitable carburetor ( the lectron would have been great, I regret selling it) I can't weld the frame myself because it's chromoly steel, and probably needs to be tig welded. At this point it's a matter of getting the funds ( I'm deep in the hole with the budget here &#128517 and getting these parts together.


I'll get some pictures of the engine and frame, this bike is gonna look a little odd, full size wheels on a 50cc frame.
Sorry for the wall of text lol.