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Maxi Scooter

Product

Overview

A maxi scooter takes the step-through, twist-and-go convenience of a small scooter and scales it up to motorcycle-class performance. With a twin-cylinder engine, full-size wheels, a long wheelbase, and a fairing that shelters the rider from highway wind, it is built for riders who want to commute long distances or cover motorway miles without operating a clutch and gearbox.

The machine is assembled from a stiff twin-spar frame, a frame-mounted engine unit, a front end and rear end, a braking system with ABS, enclosing bodywork, the fuel system, the electronics, and a comfort-oriented cockpit.

Frame and engine mounting

Unlike a small scooter, where the engine swings as the suspension arm, a maxi scooter mounts the engine rigidly in a stiff twin-spar frame. Two spars tied by cross braces run from the headstock to a rear subframe, with an engine cradle holding the powerplant low and forward. Fixing the engine to the frame and driving the rear wheel through a separate swingarm sharply reduces unsprung weight, which is what lets a maxi scooter handle at highway speed where a small scooter would wallow.

Engine and CVT

The engine is a liquid-cooled parallel-twin of around 530 cc with a crankcase, a cylinder block, two pistons on a crankshaft, a twin-cam DOHC head, a valvetrain, and two spark plugs. Liquid cooling through a radiator, water pump, and thermostat lets it sustain high output without the overheating a small air-cooled engine would suffer. Drive remains automatic: the CVT and final drive uses a variator, a V-belt, a centrifugal clutch, and a driven pulley feeding reduction gears in a gearbox housing.

Suspension, wheels and brakes

The front end uses a long-travel telescopic fork with damper cartridges and springs, carrying a 14 to 15 inch front wheel far larger than a small scooter's, for stable high-speed road holding. The rear end is a proper aluminium swingarm on twin shocks. The brake system is full motorcycle grade: dual front and single rear calipers, two master cylinders, and an ABS modulator with wheel speed sensors that combines anti-lock and linked braking.

Bodywork and storage

The bodywork is a full fairing built for distance. A front fairing and an adjustable windscreen, raised and lowered by a small motor, create a calm pocket of air behind the screen. Side fairings and a flat floorboard protect the legs, the two-up seat is wide and often heated, and the large underseat storage box swallows two full-face helmets, the practical headline feature of the class.

Electronics and cockpit

The fuel system runs pressurised injection into twin throttle bodies. The electronics are car-like: a ride-by-wire ECU managing traction control and ride modes, a battery, alternator, starter, a keyless ignition module, and LED lighting. The cockpit adds a TFT dashboard, heated grips, and adjustable controls for all-weather comfort.

Comfort and weather protection

A maxi scooter is bought largely for the way it shelters its rider, so a great deal of the engineering goes into comfort that a sport motorcycle ignores. The adjustable windscreen is sized so that, raised, it routes the airflow over the rider's helmet and removes the constant buffeting that makes long motorway runs tiring on a naked bike. The front fairing and side fairings extend that shelter down to the legs and feet, and on premium models a heating element in the seat and the heated grips keep the rider warm in cold weather. The riding position is upright and the floorboard lets the rider plant both feet flat at rest, which makes the heavy machine easy to manage in stop-start traffic despite a kerb weight that can exceed 230 kg.

Variants

The class spans roughly 250 cc commuter machines up to flagship 750 cc tourers with cornering ABS, radar-assisted cruise control, and integrated hard luggage. Smaller versions stay light and air-cooled for city duty, while the largest blur into the touring motorcycle segment, offering wind protection and weather equipment that a conventional tourer cannot match. Throughout the range the constants are the automatic CVT transmission and the step-through ergonomics that distinguish a scooter from a motorcycle, however large the engine becomes. Electric maxi scooters are now entering the market, replacing the engine and tank with a battery and motor while keeping the fairing, storage, and relaxed riding position intact.

Maxi Scooter parts and their functions

9 top-level parts · 559 parts in total · full bill of materials below
Maxi Scooter parts diagram: 1 twin-spar frame, 2 engine unit, 3 front end, 4 rear end, 5 brake system (ABS), 6 bodywork, 7 fuel system, 8 electronics, 9 cockpit. 559 parts in 9 top-level items.
Maxi Scooter parts diagram. Numbers match the table below; each box is one top-level part or assembly with what it contains.
#PartQtyWhat it does
1 Twin-Spar Frame 7 parts 1× Twin-spar step-through frame
2 Engine Unit 12 parts 1× Twin-cylinder CVT engine
3 Front End 4 parts 1× Fork, wheel and front brakes
4 Rear End 4 parts 1× Swingarm, wheel and rear brake
5 Brake System (ABS) 5 parts 1× Linked ABS hydraulics
6 Bodywork 8 parts 1× Fairing, screen and storage
7 Fuel System 5 parts 1× Tank and injection
8 Electronics 9 parts 1× ECU, ride aids and lighting
9 Cockpit 7 parts 1× Bars, TFT dash and comfort

3D model

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Build & assembly graph

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Bill of materials for Maxi Scooter

9 top-level lines · 133 rows shown · 559 parts total · indented to 3 levels
# Item / sub-assembly Part no. Qty/assy Ext. qty Parts Type
1 Twin-Spar Frame 7 parts maxi-scooter-frame 1× 1 10 assembly
1.1 Frame Spar maxi-scooter-spar 2× 2 · part
1.2 Cross Brace maxi-scooter-cross-brace 2× 2 · part
1.3 Rear Subframe maxi-scooter-subframe 1× 1 · part
1.4 Steering Headstock maxi-scooter-headstock 1× 1 · part
1.5 Engine Cradle maxi-scooter-engine-cradle 1× 1 · part
1.6 Ball Bearing ball-bearing 2× 2 · part
1.7 Fastener Set fastener-set 1× 1 · part
2 Engine Unit 12 parts maxi-scooter-engine 1× 1 48 assembly
2.1 Crankcase maxi-scooter-crankcase 1× 1 · part
2.2 Cylinder Block maxi-scooter-cylinder-block 1× 1 · part
2.3 Piston & Rings maxi-scooter-piston-set 2× 2 · part
2.4 Crankshaft maxi-scooter-crankshaft 1× 1 · part
2.5 Cylinder Head (DOHC) maxi-scooter-cylinder-head 1× 1 · part
2.6 Valvetrain 3 parts maxi-scooter-valvetrain 1× 1 11 assembly
2.6.1 Camshaft maxi-scooter-camshaft 2× 2 · part
2.6.2 Valve maxi-scooter-valve 8× 8 · part
2.6.3 Cam Chain maxi-scooter-cam-chain 1× 1 · part
2.7 CVT & Final Drive 8 parts maxi-scooter-cvt 1× 1 12 assembly
2.7.1 Drive Variator maxi-scooter-variator 1× 1 · part
2.7.2 Drive Belt drive-belt 1× 1 · part
2.7.3 Centrifugal Clutch maxi-scooter-clutch 1× 1 · part
2.7.4 Driven Pulley maxi-scooter-driven-pulley 1× 1 · part
2.7.5 Helical Gear Pair gear-pair 2× 2 · part
2.7.6 Gearbox Housing gearbox-housing 1× 1 · part
2.7.7 Ball Bearing ball-bearing 3× 3 · part
2.7.8 Oil Seal oil-seal 2× 2 · part
2.8 Liquid Cooling 5 parts maxi-scooter-cooling 1× 1 8 assembly
2.8.1 Radiator maxi-scooter-radiator 1× 1 · part
2.8.2 Water Pump maxi-scooter-water-pump 1× 1 · part
2.8.3 Thermostat maxi-scooter-thermostat 1× 1 · part
2.8.4 Cooling Fan maxi-scooter-cooling-fan 1× 1 · part
2.8.5 Coolant Hose maxi-scooter-coolant-hose 4× 4 · part
2.9 Spark Plug spark-plug 2× 2 · part
2.10 Ball Bearing ball-bearing 4× 4 · part
2.11 Oil Seal oil-seal 4× 4 · part
2.12 O-Ring Set oring-set 1× 1 · part
3 Front End 4 parts maxi-scooter-front-end 1× 1 17 assembly
3.1 Telescopic Fork 5 parts maxi-scooter-fork 1× 1 9 assembly
3.1.1 Fork Tube maxi-scooter-fork-tube 2× 2 · part
3.1.2 Damper Cartridge maxi-scooter-fork-cartridge 2× 2 · part
3.1.3 Coil Spring coil-spring 2× 2 · part
3.1.4 Oil Seal oil-seal 2× 2 · part
3.1.5 Triple Clamp maxi-scooter-triple-clamp 1× 1 · part
3.2 Front Wheel 4 parts maxi-scooter-front-wheel 1× 1 5 assembly
3.2.1 Cast Alloy Rim maxi-scooter-rim 1× 1 · part
3.2.2 Tyre maxi-scooter-tire 1× 1 · part
3.2.3 Ball Bearing ball-bearing 2× 2 · part
3.2.4 Wheel Axle maxi-scooter-axle 1× 1 · part
3.3 Front Fender maxi-scooter-front-fender 1× 1 · part
3.4 Front Brake Disc maxi-scooter-front-disc 2× 2 · part
4 Rear End 4 parts maxi-scooter-rear-end 1× 1 12 assembly
4.1 Swingarm maxi-scooter-swingarm 1× 1 · part
4.2 Rear Shock Absorber 3 parts maxi-scooter-rear-shock 2× 2 3 assembly
4.2.1 Shock Body maxi-scooter-shock-body 1× 2 · part
4.2.2 Coil Spring coil-spring 1× 2 · part
4.2.3 Oil Seal oil-seal 1× 2 · part
4.3 Rear Wheel 3 parts maxi-scooter-rear-wheel 1× 1 4 assembly
4.3.1 Cast Alloy Rim maxi-scooter-rim 1× 1 · part
4.3.2 Tyre maxi-scooter-tire 1× 1 · part
4.3.3 Ball Bearing ball-bearing 2× 2 · part
4.4 Rear Brake Disc maxi-scooter-rear-disc 1× 1 · part
5 Brake System (ABS) 5 parts maxi-scooter-brake-system 1× 1 113 assembly
5.1 Brake Caliper 4 parts maxi-scooter-caliper 3× 3 6 assembly
5.1.1 Caliper Body maxi-scooter-caliper-body 1× 3 · part
5.1.2 Caliper Piston maxi-scooter-caliper-piston 2× 6 · part
5.1.3 Brake Pad maxi-scooter-brake-pad 2× 6 · part
5.1.4 O-Ring Set oring-set 1× 3 · part
5.2 Master Cylinder maxi-scooter-master-cylinder 2× 2 · part
5.3 ABS Modulator 5 parts maxi-scooter-abs-modulator 1× 1 87 assembly
5.3.1 Bare PCB pcb-bare 1× 1 · part
5.3.2 Microcontroller mcu 1× 1 · part
5.3.3 ABS Pump maxi-scooter-abs-pump 1× 1 · part
5.3.4 Solenoid Valve maxi-scooter-solenoid-valve 4× 4 · part
5.3.5 SMD Passive (R/C/L) smd-passives 80× 80 · part
5.4 Braided Brake Line maxi-scooter-brake-line 4× 4 · part
5.5 Wheel Speed Sensor maxi-scooter-wheel-speed-sensor 2× 2 · part
6 Bodywork 8 parts maxi-scooter-bodywork 1× 1 13 assembly
6.1 Front Fairing maxi-scooter-front-fairing 1× 1 · part
6.2 Adjustable Windscreen 2 parts maxi-scooter-windscreen 1× 1 2 assembly
6.2.1 Screen Panel maxi-scooter-screen-glass 1× 1 · part
6.2.2 Screen Adjust Motor maxi-scooter-screen-motor 1× 1 · part
6.3 Side Fairing maxi-scooter-side-fairing 2× 2 · part
6.4 Floorboard maxi-scooter-floorboard 1× 1 · part
6.5 Two-Up Seat 4 parts maxi-scooter-seat 1× 1 4 assembly
6.5.1 Seat Base maxi-scooter-seat-base 1× 1 · part
6.5.2 Seat Foam maxi-scooter-seat-foam 1× 1 · part
6.5.3 Seat Cover maxi-scooter-seat-cover 1× 1 · part
6.5.4 Heating Element heating-element 1× 1 · part
6.6 Underseat Storage Box maxi-scooter-storage-box 1× 1 · part
6.7 Rear Fairing maxi-scooter-rear-fairing 1× 1 · part
6.8 Fastener Set fastener-set 1× 1 · part
7 Fuel System 5 parts maxi-scooter-fuel-system 1× 1 9 assembly
7.1 Fuel Tank maxi-scooter-fuel-tank 1× 1 · part
7.2 Fuel Pump maxi-scooter-fuel-pump 1× 1 · part
7.3 Throttle Body 2 parts maxi-scooter-throttle-body 2× 2 2 assembly
7.3.1 Throttle Plate maxi-scooter-throttle-plate 1× 2 · part
7.3.2 Pressure Sensor pressure-sensor 1× 2 · part
7.4 Fuel Injector maxi-scooter-injector 2× 2 · part
7.5 Air Box & Filter maxi-scooter-air-box 1× 1 · part
8 Electronics 9 parts maxi-scooter-electronics 1× 1 204 assembly
8.1 Engine & Ride ECU 4 parts maxi-scooter-ecu 1× 1 144 assembly
8.1.1 Bare PCB pcb-bare 1× 1 · part
8.1.2 Microcontroller mcu 2× 2 · part
8.1.3 CAN Transceiver can-transceiver 1× 1 · part
8.1.4 SMD Passive (R/C/L) smd-passives 140× 140 · part
8.2 12 V Battery maxi-scooter-battery 1× 1 · part
8.3 Alternator maxi-scooter-alternator 1× 1 · part
8.4 Regulator / Rectifier maxi-scooter-rectifier 1× 1 · part
8.5 Starter Motor maxi-scooter-starter 1× 1 · part
8.6 Keyless Ignition Module 4 parts maxi-scooter-keyless 1× 1 43 assembly
8.6.1 Bare PCB pcb-bare 1× 1 · part
8.6.2 Microcontroller mcu 1× 1 · part
8.6.3 RFID Coil maxi-scooter-rfid-coil 1× 1 · part
8.6.4 SMD Passive (R/C/L) smd-passives 40× 40 · part
8.7 LED Lighting Set 3 parts maxi-scooter-lights 1× 1 6 assembly
8.7.1 LED Headlight maxi-scooter-headlight 1× 1 · part
8.7.2 LED Tail Light maxi-scooter-tail-light 1× 1 · part
8.7.3 Turn Indicator maxi-scooter-indicator 4× 4 · part
8.8 Wire Bundle wire-bundle 1× 1 · part
8.9 Relay relay 6× 6 · part
9 Cockpit 7 parts maxi-scooter-cockpit 1× 1 133 assembly
9.1 Handlebar maxi-scooter-handlebar 1× 1 · part
9.2 Throttle Grip maxi-scooter-throttle-grip 1× 1 · part
9.3 Brake Lever maxi-scooter-brake-lever 2× 2 · part
9.4 Switch Cube maxi-scooter-switch-cube 2× 2 · part
9.5 TFT Dashboard 4 parts maxi-scooter-tft-dash 1× 1 123 assembly
9.5.1 Bare PCB pcb-bare 1× 1 · part
9.5.2 Microcontroller mcu 1× 1 · part
9.5.3 LCD Panel lcd-panel 1× 1 · part
9.5.4 SMD Passive (R/C/L) smd-passives 120× 120 · part
9.6 Heated Grip maxi-scooter-heated-grip 2× 2 · part
9.7 Mirror maxi-scooter-mirror 2× 2 · part

Sourcing: possible vendors

Browse the supplier directory → Prices, MOQ, and lead times are algorithmic estimates, not quotes, and not claims about these companies. Company mappings are curated by keyword; est. price band $300–$15k. How estimates work
VendorHQSpecialtyMOQLead time
global.honda ↗ Tokyo, JP Motorcycles & power products made to order 10–16 wks
🇯🇵Yamaha Motor
yamaha-motor.com ↗
Iwata, JP Motorcycles & marine made to order 10–16 wks
heromotocorp.com ↗ New Delhi, IN Motorcycle & scooter maker made to order 10–16 wks
🇮🇳Bajaj Auto
bajajauto.com ↗
Pune, IN Two- & three-wheeler maker made to order 10–16 wks
harley-davidson.com ↗ Milwaukee, US Motorcycles made to order 10–16 wks

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