tgb 202 classic 62 plate

hi my son has been buying the above bike and we are after some advice on cheap tuning mods and where best to buy parts thanks in advance. scott

 

adrenaline pedstop
pedparts
euroscootershop

first place would be free up some speed, we can do this by derestricting the Variator.
you would remove the left hand sidecase to the engine , under here is your belt drive system and we are interested in the front part it comes in two piece the front round plate is called a fixed pulley half its held on by a nut that secures it to the crankshaft, you would zip that off with an impact gun.

once the fixed half plate is removed you will notice the belt and usually a wedding ring like washer that slips over a large boss , this small ring is a restricton ring it stops the front variator drive system from fully closing and forcing the belt high up on that fixed half plate. the higher that belt rides on the front pulley the higher the top speed is to a point. Right now your sons 202 classic is going to be heavly restricted to 30mph, the removal of this washer allows the belt to raise higher so you should have a higher top speed. this is the most basic free no cost Mod for a slight speed upgrade.

the next in line is the roller weights you will find these in the front variator, 9-10 times they tend to be fairly heavy stock factory installed rollers usually around 7g to 8g in weight, for around £6 - £10 you can buy a new set of rollers and install them an ideal weight is 6g. what this does is allows the engine to rev higher , you will find the scooter a little more peppy from the lights and pulling away you will notice it holds the rpm to instead of a high rpm then tailing off , you will find the rpm his high and stays high so you harness all the power the motor produces.

the most expensive part is exhaust , this is the main power killer in scooters they are highly restricted, most if not all scooter tuners will swap these stock exhausts out for a sports exhaust, just doing this can add an extra 2-3hp to the engines power output , when you replace an exhaust for a less restrictive exhaust you MUST do a re-jet on the carb, what this means is replacing the stock main fuel jet with a larger one we tend to go with a 10% increase in size ( ie a stock 56 jet would be replaced with a 65-66 main jet), this means you get more fuel and a bigger bang and that all gives a higher top speed and more power it is the norm to rejet when you add a new exhuast and allows you to get the engine running just perfect. from factory the engines are set to run very lean to comply with emissions tests, when we rejet we adjust the engine so it runs slightly rich its great for the engine and prolongs the life of the internals , keeps heat down and overal the scooters engine runs a lot more happy.

FORGET all these fancy airfilters he maybe pushed towards the stock airfilter on the scooter will be fine for a derestricted scooter if you re-jet and derestrict the exhaust and remove the variator restriction.

MYTHS n granny tails ..........

we often hear younguns saying " my scooter does 60mph and its got this this and this " usually this is just a straight forward derestriction but the real truth is this, the small scooter engine will push you upwards 40-45mph very rare you will see 50-55mph and thats rare and usually with very expensive branded named scoots like an aerox or a zip, so you must get son to understand his scoot may not be as fast as his mates or faster that others its all down to the scooters motor and these days they are low power , most younguns have this quest for the most fastest scooter going but these little motors just dont have that sort of power unless a LOT OF MONEY IS SPENT and a good 20+ HR of tinkering is done to get them set up. just to show a 70cc bore kit can cost upwards of £100+ but with that you have to upgrade to a larger carb and they alone can cost upwards £60 then theres the rejetting, a new open filter system and the countless hours tinkering and pulling sparkplugs checking the burn state. and all this only shoves an extra 20mph 25-mph onto the top end of 45mph your looking at 200 quid for 25mph extra . to get even more speed means tearing apart the rear gearbox and adding new primary gearing its not an easy job and again costs more pennys. if your scooter hits 40-45mph or a little faster derestricted you done a good job and should leave it at that, any more tuning means faster wear and added costs.

 

That's great thanks for the advice it looks like the front part of my variate is held on with 3 Allen keys is that right? Also where are the variations weights located please ?

 

Sorted variator derestricted thanks again gonna buy some weights next cheers

 

No the variator is held onto the crank itself by a large 18mm nut , what you need to do is stand behind the bike , the left hand side of the engine there is a large cover plate it goes from center of rear wheel all the way upto front of the engine, this is the variator/transmission cover we Have to remove that first its usually held on with around 8 bolts. if you scooter has a kickstarter thats the side plate you need to remove.

now once transmission cover is removed under it will the the transmission, up the front towards the front wheel you will see a round disc , thats the variator its held on by a large nut , it needs to be removed with an inpact gun (torque gun). let me find a video you can watch, nearly all scooters are the same transmission wise ie how they work.

 

Yeh iv sorted it mate thanks any idea wot carb fits this bike does a Peugeot or some other make fit it please

 

you wont need a carb if your just going to add a sport pipe , just need to take carb off, undo the bottom of the carb (float bowl) then look at the large jet, its a bras colour and will have a screwdriver slot in it, usually its cetral in the carb between the carb floats, ontop of that jet or around its edge should be a number thats the jet size. with a sport pipe added you will tend to go up by around 10% in jet size ( give or take ).

re-jetting is fiddly and usually means you need to get a few jet sizes to test out what gives the best preformance.

carb wise a dellorto 17.5mm carb would be a good upgrade from the stock 12-14mm carb fitted, problem is you would need to find a aftermarket manifold to fit carb to bike as the tgb i think are a flange type fitment and not a push fit to rubber hose type as a bigger carb will be.

 

Tha