Replacing generic chinese scooter body? By digitalman (Read 3,374 times)

[digitalman]

So I just picked up a Manco Hornet 50 for $65. It nearly runs, and for about $100 in parts I'll be able to make thing thing run properly, and maybe even stop! However, that's just the mechanical portion of this project.

This scooter has clearly been sitting out for a long time, and probably fell over and/or took a long drive off a short cliff. Every light lens is outright opaque, and I'm honestly not sure if the body plastic was ever smooth to begin with; it has some severe damage just from the elements, to say nothing of various cracks and missing chunks. The top plastic that goes over the handlebars, needed to support the headlight and instrument cluster, is just plain gone.

Now, GY6 engine components are generally standard with only a few variations, and things like brake levers also have common trends that make replacement cheap and easy. Unfortunately, body panels seem entirely unique by model, and I'm unlucky enough to have one that just wasn't popular enough to have readily available replacements.

So the question basically is, how standardized is the frame? If I were to obtain a full plastic set for any hey-that-looks-similar 50cc chinese scooter, is it apt to just fit right into place? The asymmetrical mounting points on the handlebars especially worry me, but at the same time they served no purpose for this scooter, so maybe that's also normal...

[kz1000st]

Actually it depends on the body style. GS Motorworks carried all sorts of styles over the years and can supply some body parts. John at scootersus.com is another source. If you supply a picture maybe someone will make suggestions.

[jct842]

Usually by the time you buy all the plastic you might just as well have bought a new scooter when you figure your time and what money you already have in it. Getting all the pieces in a matching color is also a problem too. If it was me I would ride it naked as a good value, the more you put in a used scooter the less of a good deal it becomes. Some times a person can run across a user that has a blown engine for little or nothing. With good plastic and a different body style you just swap engines and away you go.

[digitalman]

After completely removing all the plastic body panels, I'm actually pleased with what I've found. There are a number of mount points on the frame that outright aren't used, effectively proving that something else out there uses the same frame, though I know not what. I took dozens of pictures during the disassembly, but I'm not sure which ones would be useful in identifying replacement parts or a body swap.

Thankfully, using it "naked" may actually work for the most part. The seat (which does need replacing) is supported by nothing but the bucket beneath it, the floorboard bolts right to the frame, and the rear lights and fender function as more of a base for everything else to screw into, so they support themselves just fine. May even be able to use the front panels alone to reduce drag, and hold the turn signals. That does leave me still needing the headlight and speedometer holders, but they obviously don't have to bolt to any other parts. I'm hoping for something with hand-guards and a windshield

Also, this is the exact speedometer the Manco Hornet comes with. It being sold so generically tells me that something else must use it, and therefore (probably) have suitable plastic around it.

[shop242]

I Hate chinese body work. I have the full dress Cozumel and had to change headlamp bulbs.. 600 screws and 50 broke clips and plastic later, I had to whip out the ole duct tape. Its cheap chit! Trust me..