Glutton for Punishment - 1992 Honda Dio 2

[hippo008]

Well it happened. I finally got rid of the Roughhouse. I couldnt stand wrenching on it anymore. I traded the Roughhouse away for a Honda Dio 2 and cash. The bike was built by an absolute moron. Its so poorly setup it blows my mind. Im not sure the plans for this bike as of yet but im tempted to just fix it and flip it. Its pretty clapped out looking but she has it where it counts. Solid motor and an almost spotless frame.

It currently has a Polini Corsa, PG crank, aftermarket suspension, aftermarket alloy wheels, aftermarket brakes a Jayaco JDM exhaust and is missing some plastics.

[Sum-azn-kid]

The bore and crank is a good combination Im running that same set up. That shroud is a no go. Missing the outer cover... Did they give u the missing panels?

[hippo008]

I broke down the Dio today. Its an AF27 model. At some point somebody came through and did a disk brake swap. The headset is aftermarket and has the master cylinder hole. The master itself is an OEM Honda part so whomever did the conversion did a good job. The rest of the bike is clean. The gas tank is completely rust free. The frame is essentially rust free, i wont need to strip and POR15 the whole thing which is a plus. 







Some of the panels were cracked and damaged so I patched them up with some structural plastic epoxy. Tomorrow ill sand out the inside and use some small fiberglass patches to add some structure to the area. The panels are scratched so I will need to repaint them. Im thinking a deep green could be nice. Im not sure how to paint ABS. If anybody has any tips let me know. 









I broke down the engine and the guy who did the performance build was a bigger moron than expected. He used no gaskets or gasket sealer anywhere in the motor. They decided to not use any nuts on any of the engine hangars or on the intake. He just slapped em on there and hoped for the best. The used rusted out CVT components and called them good. Frankly im amazed this thing ever ran at all. 





This is why I dont like buying anything somebody else has worked on. Its almost always done to a much lower standard of quality than I am happy with. Fortunatly for me everything is there that really needs to be there. OEM gauge cluster, all the panels, clean frame and gas tank. 

I decided to remove all the ugly "bling" the second builder installed. I used some EasyOff oven cleaner to strip off the anodizing on some parts. If anyome has a better way of cleaning parts let me know. Heres the rotor I did this evening. 

[Sum-azn-kid]

Looks like they thru the whole bunch of AliExpress parts at that dio. Looking forward to how u redo it. I did the same with my dio 1. Only used the frame, handle bars, gas tank and seat bucket. Redid everything else even new wire harness.

[hippo008]

Sept 28, 2021 20:16:22 GMT -5 Sum-azn-kid said:

Looks like they thru the whole bunch of AliExpress parts at that dio. Looking forward to how u redo it. I did the same with my dio 1. Only used the frame, handle bars, gas tank and seat bucket. Redid everything else even new wire harness.

Ive used some AliExpress parts on my first dio build. It seems like a real mixed bag in terms of quality. Ive been very happy with my brake rotors, seat cover and plastics but ive also literally thrown away other stuff.

It seems like the parts this guy chose were of the shit variety. I want to keep the budget low on this build so I want to try and re-use as much as I can. Im going to remove as much "bling" as I can and strip everything else.

Dark green emerald panels, black inner plastics and white wheels are my plan so far.

[hippo008]

I made some headway with the gas tank. I used a stainless steel brush and degreaser. After a few scrubbings and rinses it was clean. Theres a few small rust spots but *way* better than my other tank. Its so much nicer im going to restore this one and swap it onto Quarantine Killer.

Before





After






I used some phosphoric acid to etch the surface to prep for POR15. I totally recommend this stuff to anyone. Its expensive but it really seriously works. It totally neutralizes rust and is basically permanent.

Heres the first coat of two

[aeroxbud]

Making a nice job of that.
The amount of other people's shoddy work I've fixed on bikes is unbelievable. It drives you crazy right?

[hippo008]

Oct 1, 2021 17:00:50 GMT -5 aeroxbud said:

Making a nice job of that.
The amount of other people's shoddy work I've fixed on bikes is unbelievable. It drives you crazy right?

This bike was setup in the craziest way. I support people learning how to wrench on their own stuff. I’m self taught so I totally get the learning curve that comes with it. What’s crazy is that some people just simply don’t care to do it even kind of right, they just wing it and don’t care. I’m part of a large Facebook group for scooter tuning. It’s notorious for its “mechanics” doing some silly stuff. I’ve seen crankshafts installed with hammers. I saw somebody install an ignition so wrong the bike ran backwards, literally the bike ran in reverse. This Dio came out of that group. It’s the bike life crowd, the people who ride with no tags and ride wheelies on dirt bikes and quads downtown. It amazes me that they don’t take any pride in a job well done. 

[hippo008]

Sept 27, 2021 21:52:36 GMT -5 Sum-azn-kid said:

The bore and crank is a good combination Im running that same set up. That shroud is a no go. Missing the outer cover... Did they give u the missing panels?

Do you have any lines on shrouds in Hawaii? Ive looked around here and people want $100+ for cracked OEM shrouds.

[Sum-azn-kid]

Ive seen new ones selling for around that much on Hawaii FB. Some times even on ebay. If u dont find any DM me i have some spare used ones.

[hippo008]

I struck oil!

The new AF27 (still needs a name, hit me with some ideas) was missing the side skirts and the black wheel shroud plastic. I looked around locally and didnt find anything for less than $400. On AliExpress or Yahoo! Auctions Japan you can get sets pretty cheap but the shipping is $200+ to my area. I decided to try something new and I took a look around WeBike Japan. I found a plastics kit that included the wheel cowling and the side skirts for only ¥7700 ($70) shipped. Thats a screamin' deal as far as im concerned. I figured they would be brittle as biscuits and a poor fit but I was totally wrong. They were also shipped VIA EMS, a usually high-end shipping option. They arrived in less than a week as opposed to months from AliExpress.

[hippo008]

I got a new TWH intake and Corsa gasket kit in today. I went to install them onto the bike and it went well. I tried to rotate the crank around a few times to check the feel and I heard a nice CLUNK. Turns out there is a mini-stroker crank installed onto this bike.

So to make this thing run I have a few options. I could use more base gaskets to space the cylinder up and set my squish at like .8~mm. I could also try and space out just the head to try and take advantage of the additional stroke and keep the port timing the same. I know I could cutout a few paper base gaskets and go that route. However I dont think I can safely make a head gasket out of gasket paper, can I? What would yield better performance in this case?

I am tempted to try and just space out the head but I am nervous to use a paper head gasket.

[repherence2]

Oct 19, 2021 14:48:36 GMT -5 hippo008 said:

I got a new TWH intake and Corsa gasket kit in today. I went to install them onto the bike and it went well. I tried to rotate the crank around a few times to check the feel and I heard a nice CLUNK. Turns out there is a mini-stroker crank installed onto this bike.

So to make this thing run I have a few options. I could use more base gaskets to space the cylinder up and set my squish at like .8~mm. I could also try and space out just the head to try and take advantage of the additional stroke and keep the port timing the same. I know I could cutout a few paper base gaskets and go that route. However I dont think I can safely make a head gasket out of gasket paper, can I? What would yield better performance in this case?

I am tempted to try and just space out the head but I am nervous to use a paper head gasket.

Scooter Swap Shop might sell the ministroker spacers for the bore. I see them pop up on Craigslist Oahu. There is someone here on Oahu that sells the ministroker spacers in 3 different thickness. Machined aluminum spacers. I take it that it is a better option than stacking paper gaskets.

[hippo008]

I assembled the motor today. I ended up using two paper base gaskets the some Motoseal to seal up the stacked gaskets. The bike came with a Sunworld PWK 28mm carb. It has a power jet and some ports im not familiar with. I think they are overflow ports but im not sure. Im also not familiar with powerjets either. Im not sure what they are really for, is it just to add more fuel WOT outside of the main jet? Here are those strange ports. 




When I cranked over the motor it idles very high. Im not sure if its just a small main jet or I have an airleak. Ill put the pressure tester on it tomorrow to check it. 

It turns out the motor is also an AF16E and not the AF18E. Normally I wouldnt mind but its a problem in this case. There is no vacuum port on the cases to operate the fuel pump. So to solve the problem I am going to modify the oil pump plug to have a nipple for some vacuum tube. Ill post the results tomorrow. 

[Sum-azn-kid]

Those might be vents. My cr85 with a keihin pwk28 has nipples on both side for vent hoses.


Hard to say for sure ive only dealt with keihin and some oko carbs.