What I'm not trying to do:
an engine swap, or
an accurate ATC70 restore
a super performance mod ATC70.

Ok so what am I trying to do? I want to take the atc from my child hood and with other frames and parts slowly start building, from scratch, an ATC70 with a new electric start chinese engine, and reusing as many original parts as possible (except plastics and rubber parts).

So what have I done so far?
Nothing.

What have I bought so far?
From TBoltUSA.com:
110cc Piranha 3spd w/reverse ($279),
17T Sprocket (420size) ($18),
Chinese 12v Wiring Harness ($17),
Trail Bikes Air Filter 20MM-24MM CARB ($12),
HRC Coil ($20),
12 Way Carb Kit ($19), and
Mikuni 22mm Carb Kit ($85).

Here's what I've discovered:
1) the manifold that comes with the engine (even though I didn't know the engine came with one) and the manifold that came with the carb kit will not fit on the engine with the carb. (manifolds fit to engine, carb fits to manifold, but the three won't fit together. Either the starter, or a cooling fin, or the valve spring cover are in the way.)
2) the 12 way carb kit looks nice but there is a giant "divit" machined out of it for no apparent reason. It looks like a mistake but when you look at the picture online you can see where the divit is if you look closely (to the side facing away from the camera). [EDIT: I've heard from TBoltUSA and they say that's the way they are. I've also since seen some pictures and realized that the "divit" is there so that it clears the valve cover on the head of smaller engines like 50cc's.]
3) the 12 way carb kit + the manifold that came with the engine + the Mikuni 22mm carb assembly WILL fit if you place it facing forward [EDIT: or off to a side].
4) the 20mm-24mm Air Filter just barely fits over the intake of the 22mm carb. I pity people with a 24mm carb and this filter b/c I doubt it'd work.
5) the "Chinese 12v wiring harness" seems to mate up to one of the engines pig tails but the other one uses a plug that doesn't match anything on the "Chinese 12v wiring harness". [EDIT: see the story about the wiring harness below]

So I'll post more "lessons" or thoughts (and hopefully pictures also) soon. In the mean time does anyone else have any ATC70 build pointers, lessons, or warnings to offer this 1st time trike builder.

Thanks,

Celebrity208 (aka Clayton)

So here are the pictures of most of the parts that I purchased.

http://picasaweb.google.com/claytootie/20100224ByEyeFi#

I wasn't sure what was going on with the wiring harness and everything coming out of the engine at first but I've since figured a bunch out. The wiring harness has two plugs that are identical to each other and coincidentally also match a plug coming out of the engine. So, explanations:

The engine:
There are two wiring harnesses coming out of the engine. One from the stator and one from the transmission position sensor. To be sure which is which I removed the sprocket cover exposing the transmission sensor. These wires will not be used (for now) in my build. The stator wire harness (for this engine) had a yellow wire (Y), a yellow wire with Chinese characters on it (Y-C), a blue-white (Bu-W) wire, and a black-red (Bk-R) wire.

The wiring harness:
This had 3 white plastic plugs, a green ground (I assume), and two loose wires with female blade connectors black-yellow (Bk-Y) and green (G). These last two go to the ignition coil so that leaves us with the 3 plastic plugs. Of the 3 two are the same plug and the 3rd has only two wires and is noticeably smaller than the others. This plug is for the kill switch. One of the remaining plugs has 5 wires [black-red (Bk-R), black-yellow (Bk-Y), black-white (Bk-W), blue-white (Bu-W), and green (G)] and the other has 3 wires [black-red (Bk-R), blue-white (Bu-W), and green (G)]. The 5 wire plug goes to the CDI unit and the 3 wire plug goes to the engine stator wire.

This wiring diagram has helped me a ton: http://www.tboltusa.com/Tech_Data/index.ph...ing-with-lights


In my situation I need to either splice, make my own plug, or find an adapter so that I can connect the wiring harness to the engine. More to come...

Oh, I forgot to mention that I got my rolling frame modified. I bought a decent shape rolling chassis ATC70 and took it to a weld shop where they lengthened the frame 1.25" in the tube section of the frame. Pictures to come later. This is so that the fender will clear the engine's head since this the 110cc is about .5" longer and ATC70s never really had a ton of clearance. I suspect it will also make the riding position a little more comfortable for adults too.

-c-

Keep us up to date on your progress.

Also that adapter 12 point plate for the carb seems to raise the carb up where it will hit the tank regardless of the angle. At least thats what it did for me. Sounds like a fun build...

Get the HRC short intake from tbolt, that and the 12 way adapter. I took a ball peen hammer and knocked a dent to the inner side of the tank. A 50 cent piece size dent allows the carb cap to clear.